Rear impact guard

ABSTRACT

A rear impact guard configured to be coupled to a rear end of a trailer includes first, second, third, and fourth support bases coupled to a the rear end of the trailer, first, second, third, and fourth bumper support members associated with the first, second, third, and fourth support bases, respectively, and a bumper mounted to lower ends of the first, second, third, and fourth bumper support members.

CROSS REFERENCE TO RELATED APPLICATIONS

The present utility patent application claims the benefit of U.S.Provisional Application No. 62/219,409, filed on Sep. 16, 2015, andentitled “Rear Impact Guard” and U.S. Provisional Application No.62/258,073, filed on Nov. 20, 2015, and entitled “Rear Impact Guard.”The entire disclosures thereof are incorporated by reference herein intheir entireties.

FIELD OF THE DISCLOSURE

The present disclosure relates generally to semi-trailers, such asvan-type trailers, for example. In particular, the present disclosurerelates to a rear impact guard for a semi-trailer and other vehicles.

BACKGROUND

The rear impact guard of a trailer, semi-trailer, and/or flatbed traileris generally provided to help prevent other vehicles in a rear-impactcollision with such a trailer from traveling beyond the rear extremityof the trailer and into an area beneath the floor assembly of thetrailer. Rear impact guards may also operate to absorb the energy of arear impact from another vehicle. Rear impact guards typically include ahorizontal member suspended from two struts attached to the bottom sideof the trailer rear end wall.

SUMMARY

The present disclosure may comprise one or more of the features recitedin the attached claims, and/or one or more of the following features andcombinations thereof.

In an illustrative aspect, a rear impact guard configured to be coupledto a rear end of a vehicle comprises first and second support basesconfigured to be coupled to the rear end of the vehicle and configuredto be positioned below a floor assembly of the vehicle, wherein thefirst and second support bases are spaced from one another along a widthof the vehicle and first and second bumper support members associatedwith the first and second support bases, respectively, wherein the firstand second bumper support members are configured to be coupled to therear end of the trailer. At least a portion of an upper surface of thefirst bumper support member may be in contact with at least a portion ofa lower surface of the first support base and at least a portion of anupper surface of the second bumper support member is in contact with atleast a portion of a lower surface of the second support base. The rearimpact guard may further include a horizontal bumper mounted to lowerends of the first and second bumper support members. The first bumpersupport member and the second bumper support member may be configured tobe coupled to the left of a longitudinal axis of the vehicle.

In another illustrative aspect, a rear impact guard configured to becoupled to a rear end of a vehicle comprises first and second bumpersupport members configured to be coupled to the rear end of the vehicleand spaced outwardly from a longitudinal axis of the vehicle and thirdand fourth bumper support members configured to be coupled to the rearend of the vehicle, the third bumper support member being spacedoutwardly of the first bumper support member and the fourth bumpersupport member being spaced outwardly of the second bumper supportmember. The rear impact guard may further include a horizontal bumpermounted to lower ends of the first, second, third, and fourth bumpersupport members. The first and second bumper support members may have afirst configuration, the third and fourth bumper support members have asecond configuration, and the first configuration is different than thesecond configuration.

In other illustrative aspects, a rear impact guard configured to becoupled to a rear end of a vehicle comprises a bumper support memberextending downwardly from and coupled to the rear end of the vehicle, ahorizontal bumper mounted at a lower end of the bumper support member,wherein the horizontal bumper extends generally perpendicular to thebumper support member, and a tube stiffener located in an interior spaceof the horizontal bumper.

In still other illustrative aspects, a bumper configured to be coupledto a rear end of a vehicle comprises a horizontal bumper mounted at alower end of the bumper support member, wherein the horizontal bumper isconfigured to be coupled to at least one bumper support member and atube stiffener located in a hollow interior space of the horizontalbumper.

In illustrative aspects, a method of retrofitting a vehicle with a rearimpact guard, the vehicle generally including a floor assembly formed bya number of slide rails, a plurality of cross members transverse to theslide rails, and a fantail coupled to a rear end of the floor assemblyis disclosed. The method may include the steps of removing at least aportion of a previously-installed rear impact guard, attaching first andsecond support blocks to at least one cross member of the floorassembly, wherein the first and second support blocks are coupledadjacent outer edges of the cross members, and attaching first andsecond outboard strapping angles to ends of the fantail. The method mayfurther include the steps of attaching the first and second supportblocks to the strapping angle, attaching first and second bumper supportmembers to the first and second outboard strapping angles, and attachinga bumper to the first and second bumper support members.

In other illustrative aspects, a method of retrofitting a vehicle with arear impact guard, the vehicle generally including a floor assemblyformed by a number of slide rails, a plurality of cross memberstransverse to the slide rails, and a fantail coupled to a rear end ofthe floor assembly is disclosed. The method may include the steps ofremoving at least a portion of a previously-installed rear impact guard,attaching first and second support blocks to at least one cross memberof the floor assembly, wherein the first and second support blocks arecoupled adjacent outer edges of the cross members, attaching first andsecond outboard strapping angles to a rear of the vehicle adjacent thefirst and second support blocks, and attaching a bumper to the first andsecond bumper support members.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A is a perspective view of a rear impact guard of the presentdisclosure showing the rear impact guard including two vertical supportmembers coupled to the underside of a rear door frame and floor assemblyof a trailer;

FIG. 1B is another view of the rear impact guard of FIG. 1A;

FIG. 2 is a perspective view of another rear impact guard of the presentdisclosure showing the rear impact guard including four vertical supportmembers;

FIG. 3 is a perspective view of a portion of the rear impact guard ofFIG. 2 showing the two inner bumper support members of the rear impactguard;

FIG. 4 is a side view of the rear impact guard of FIGS. 2-3;

FIG. 5 is a perspective view of a portion of one of the bumper supportmembers of the rear impact guard of FIGS. 2-4;

FIG. 6 is a top view of the portion of one of the bumper support membersshown in FIG. 5;

FIG. 7 is a rear view of the portion of one of the bumper supportmembers shown in FIGS. 5 and 6;

FIG. 8 is a perspective view of an alternative bumper support member ofan alternative rear impact guard (shown in FIG. 12) of the presentdisclosure;

FIG. 9 is another perspective view of the bumper support member of FIG.8;

FIG. 10 is a perspective view of a portion of the bumper support memberof FIGS. 8 and 9;

FIG. 11 is a perspective view of another portion of the bumper supportmember of FIGS. 8 and 9;

FIG. 12 is a perspective view of a rear impact guard including thebumper support member of FIGS. 8 and 9;

FIG. 13 is a perspective view of another alternative bumper supportmember similar to that shown in FIGS. 8 and 9;

FIG. 14 is a plan view of a first flat component to be formed into afirst portion of the bumper support member of FIG. 13;

FIG. 15 is a plan view of a second flat component to be formed into asecond portion of the bumper support member of FIG. 13;

FIG. 16 is a perspective view of an alternative rear impact guard of thepresent disclosure similar to the rear impact guard shown in FIG. 12 andalso including a gusset coupled to each of the bumper support members ofFIGS. 8 and 9;

FIG. 17 is a rear view of the rear impact guard of FIG. 16;

FIG. 18 is a rear perspective view one of the bumper support members ofthe rear impact guard of FIGS. 16 and 17 with the gusset attachedthereto;

FIG. 19 is a top view of the bumper support member and gusset of FIG.18;

FIG. 20 a front perspective view of the bumper support member and gussetof FIG. 18;

FIG. 21 is a perspective view of one of the gussets of the rear impactguard of FIGS. 17 and 18;

FIG. 22 is a plan view of a flat component to be formed into one of thegussets of the rear impact guard of FIGS. 17 and 18;

FIG. 23 is a top view of the gusset of FIG. 21;

FIG. 24 is a rear perspective view of an alternative bumper supportmember and gusset further including a gusset attachment coupled to a topportion of the gusset;

FIG. 25 is a front perspective view of the bumper support member,gusset, and gusset attachment of FIG. 24;

FIG. 26 is a front perspective view of the bumper support member and thegusset attachment of FIGS. 24 and 25 coupled to an alternative gusset;

FIG. 27 is a front perspective view of the bumper support member, thealternative gusset, and gusset attachment of FIG. 26, and furtherincluding a first and a second cross-brace each coupled at a first endto the gusset and at a second end to the bumper support member;

FIG. 28 is a front view of the bumper support member, the alternativegusset, the gusset attachment, and the first and second cross-braces ofFIG. 27;

FIG. 29 is a perspective view of the gusset attachment of FIGS. 24-28;

FIG. 30 is a front perspective view similar to FIG. 27 showing thebumper support member, the gusset of FIGS. 18-20, the gusset attachment,and the first and second cross-braces;

FIG. 31 is a plan view of a flat component to be formed into the firstcross-brace of FIGS. 27, 28, and 30;

FIG. 32 is a plan view of another flat component to be formed into thesecond cross-brace of FIGS. 27, 28 and 30;

FIG. 33 is a perspective view of the gusset attachment of FIGS. 24-29;

FIG. 34 is a perspective view of an alternative rear impact guard of thepresent disclosure showing the rear impact guard including four verticalsupport members coupled to the underside of a rear door frame and floorassembly of a trailer;

FIG. 35 is a perspective view of a portion of the rear impact guard ofFIG. 34 showing an outer bumper support member and an inner bumpersupport member of the rear impact guard;

FIG. 36 is a perspective view of a portion of the rear impact guard ofFIG. 34 showing an outer bumper support member including an outersupport base and an inner bumper support member including an innersupport base of the rear impact guard;

FIG. 37 is a plan view of a first flat component to be formed into afirst portion of the outer bumper support member of FIG. 34;

FIG. 38 is a plan view of a first flat component to be formed into afirst portion of the inner bumper support member of FIG. 34;

FIG. 39 is a perspective view of the outer support base of FIG. 36;

FIG. 40 is a perspective view of the inner support base of FIG. 36;

FIG. 41 is a front perspective view of a portion of the rear impactguard of FIG. 34 showing an outer bumper support member including theouter support base and an inner bumper support member including theinner support base of the rear impact guard coupled to the floorassembly;

FIG. 42 is another front perspective view of a portion of the rearimpact guard of FIG. 34 showing an outer bumper support member includingthe outer support base and an inner bumper support member including theinner support base of the rear impact guard coupled to the floorassembly;

FIG. 43 is a perspective view of an alternative rear impact guard of thepresent disclosure showing the rear impact guard including threevertical support members coupled to the underside of a rear door frameand floor assembly of a trailer;

FIG. 44 is another view of the rear impact guard of FIG. 43;

FIG. 45 is a perspective view of a portion of a rear impact guardshowing the bumper support members coupled removably to the horizontalbumper;

FIG. 46 is an exploded view of the assembly of FIG. 45 showing thebumper mounts on the horizontal bumper and the bumper support members;

FIG. 47 is a perspective view of a rear impact guard of the presentdisclosure showing the rear impact guard including four vertical supportmembers coupled to the underside of a rear door frame and floor assemblyof a trailer, and the support members removably coupled to an offsethorizontal bumper;

FIG. 48 is a perspective view of an outer support base;

FIG. 49 is a perspective view of an inner support base;

FIG. 50 is a perspective view of the offset bracket of FIG. 47;

FIG. 51 is an exploded view of a portion of the rear impact guard ofFIG. 47 showing the offset bumper mounts on the horizontal bumper andthe support members;

FIG. 52 is a side elevation view of a portion of the rear impact guardof FIG. 47 showing the horizontal bumper extended rearward of thesupport members;

FIG. 53 is a perspective view of a tube stiffener for a horizontalbumper;

FIG. 54 is a perspective view of a rear impact guard of the presentdisclosure showing two of the vertical support members, a horizontalbumper, and the tube stiffener shown in FIG. 53 welded to the exterioredge of the horizontal bumper;

FIG. 55 is a perspective view of the end detail of the horizontal bumperof FIG. 53 showing the tube stiffener coupled an exterior edge of thehorizontal bumper;

FIG. 56 is a perspective view of a rear impact guard of the presentdisclosure showing two of the vertical support members, a horizontalbumper, and the tube stiffener shown in FIG. 53 coupled to the interiorof the horizontal bumper;

FIG. 57 is a perspective view of the end detail of the horizontal bumperof FIG. 56 showing the tube stiffener coupled to the inside of thehorizontal bumper;

FIG. 58 is a perspective view of a tube stiffener for a horizontalbumper;

FIG. 59 is a perspective view of a rear impact guard of the presentdisclosure showing two of the vertical support members, a horizontalbumper, and the tube stiffener shown in FIG. 58 coupled to the exteriorof the horizontal bumper;

FIG. 60 is a perspective view of the end detail of the horizontal bumperof FIG. 59 showing the tube stiffener coupled to the exterior of thehorizontal bumper;

FIG. 61 is a perspective view of a rear impact guard of the presentdisclosure showing two of the vertical support members, a horizontalbumper, and the tube stiffener shown in FIG. 58 coupled to the interiorof the horizontal bumper;

FIG. 62 is a perspective view of the end detail of the horizontal bumperof FIG. 55 showing the tube stiffener coupled to the interior of thehorizontal bumper;

FIG. 63 is a perspective view of a support insert for a horizontalbumper;

FIG. 64 is a perspective view of the support member of FIG. 63 showingthe end of the support member welded to the horizontal tube;

FIG. 65A is a perspective view of a rear impact guard of the presentdisclosure showing the rear impact guard including four vertical supportmembers coupled to the underside of a rear door frame and floor assemblyof a trailer, the support members removably coupled to an offsethorizontal bumper, and a full-length tube stiffener located within thehorizontal bumper;

FIG. 65B is a perspective view of the rear impact guard of FIG. 65B witha support base thereof being fastened to fewer cross members of thefloor assembly of the trailer and having end clips removed therefrom;

FIG. 66 is a perspective view of a portion of a rear impact guard ofFIG. 65A showing the bumper support members coupled removably to thehorizontal bumper;

FIG. 67A is a perspective view of an offset bracket included in the rearimpact guard;

FIG. 67B is a perspective view of the offset bracket of FIG. 67A with afront wall removed therefrom;

FIG. 68 is an exploded view of a portion of the rear impact guard ofFIG. 65A showing offset bumper mounts on the horizontal bumper andbumper supports;

FIG. 69 is an exploded, partial perspective view depicting attachment ofsupport bases and bumper support members to the floor assembly of thetrailer;

FIG. 70 is a top perspective view of a bumper with inboard T-shapedbrackets and the brackets of FIG. 67A being positioned outboard of theT-shaped brackets;

FIG. 71 is an enlarged, exploded perspective view of a portion of thebumper of FIG. 69 depicting attachment of bumper support membersthereto;

FIG. 73 is a rear perspective view of a rear impact guard incorporatinginboard bumper support members from a previously-installed rear impactguard and outboard bumper support members and a bumper of the presentdisclosure;

FIG. 72 is a rear perspective view of a rear impact guard incorporatinga bumper of the present disclosure attached to four previously-installedbumper support members; and

FIG. 74 is a flow diagram depicting an exemplary process forretrofitting at least a portion of a rear impact guard of the presentdisclosure on a vehicle with a previously-installed rear impact guard.

DETAILED DESCRIPTION OF THE DRAWINGS

For the purposes of promoting an understanding of the principles of thedisclosure, reference will now be made to a number of illustrativeembodiments illustrated in the drawings and specific language will beused to describe the same.

While the concepts of this disclosure are described in relation to atruck trailer, it will be understood that they are equally applicable toother vehicles generally, and more specifically to conventional flat-bedand/or box or van type trailers, examples of which include, but shouldnot be limited to, straight truck bodies, small personal and/orcommercial trailers and the like. Accordingly, those skilled in the artwill appreciate that the present disclosure may be implemented in anumber of different applications and embodiments and is not specificallylimited in its application to the particular embodiments depictedherein.

A trailer 10 of the present disclosure includes a rear impact guard 12,also known as rear impact guard assembly 12, coupled to and dependingdownwardly from the bottom of the trailer rear frame 18, also known astrailer rear frame assembly 18, and rear end of a portion of the floorassembly 14 of the trailer 10. The rear impact guard 12 is formed as aseparate unit from a storage container (not shown) of the trailer 10 andcan be secured onto the storage container after assembly.Illustratively, the storage container includes sidewalls 16 (only one ofwhich is shown in FIG. 1A) and the floor assembly 14 coupled to andextending between the sidewalls 16. The storage container of the trailer10 further includes a rear end wall assembly 18 including an end wallframe 20 and a door (not shown) coupled to the frame 20. While a post 56may be coupled to the frame 20, illustratively it may replace the frame20 (FIGS. 34 and 43). Rear frame assembly 18 is coupled to both thesidewalls 16 and the floor assembly 14. The storage container of thetrailer 10 further includes a front end wall assembly (not shown)coupled to the sidewalls 16 and the floor assembly 14, as well as a roofassembly (not shown) coupled to the sidewalls 16 and the rear end wallassembly 18.

A pair of conventional slide rails 36 of the floor assembly 14 areattached beneath I-beam cross-members 38 (only one of which isillustratively shown in FIG. 1A) of the floor assembly, as shown inFIGS. 1A, 1B, 34, 43, 44. A conventional slidable rear undercarriageassembly (not shown) is mounted in a conventional manner to the sliderails 36. The ends of each cross-member 38 of the floor assembly 14 arecoupled to a base rail 40 of each respective sidewall 16. The base rail40 extends the length of the storage container and is preferably formedof aluminum which may be extruded.

As noted above, the floor assembly 14 includes a plurality ofspaced-apart cross-members 38 attached to the base rail 40 of eachsidewall 16. Each cross-member 38 is integrally formed from an I-beamthat includes an upper horizontal flange 42, a lower horizontal flange44, and a vertical web 46 extending between the upper and lower flanges42, 44 at the midpoint thereof. Each cross-member 38 extends across thewidth of the storage container. A floor 50, including a plurality offloor boards, generally sits on the upper surface of the cross-members38.

Slide rails 36 are connected to the underside of cross-members 38 atspaced-apart positions, and extend generally along the length of thestorage container. As is known in the art, the slide rails 36 areelongated members which include a plurality of spaced-apart apertures 52therethrough. This allows the undercarriage assembly (not shown) to besecured to the slide rails 36 at a variety of positions.

Illustratively, the rear end wall assembly 18 includes the rear frame 20which forms a rectangular opening into which the rear door or doors (notshown) are provided. The rear frame 20 includes an elongated horizontalsill 54, a pair of vertical posts 56 that extend upwardly from theopposite ends of the sill 54, and an elongated horizontal top member,i.e., rear door header, (not shown). The posts 56 are connected to therespective sidewalls 16 by rivets, but may be connected by any suitablefastener, weld, and/or adhesive. The opposite ends of the sill 54 areconnected to the respective base rails 40 by known welding, but may beconnected in any suitable manner. Illustratively, the sill 54 includes afantail 58 and a base plate 60 attached to the underside of the fantail58. As noted and seen in FIGS. 34, 43, and 44, the rear frame 20 maycomprise an extended post 56. Illustratively, sill 54 may include aplurality of spaced apart cut outs or apertures (FIGS. 34, 43, 44).

As noted above, the rear impact guard 12 is coupled to the rear end walland underside of the floor assembly 14 of the trailer 10. In particular,the rear impact guard 12 is coupled to the base plate 60 of the rearsill 54 and to the slide rails 36 of the trailer 10.

Illustratively, as shown in FIGS. 1A and 1B, the rear impact guard 12,also known as rear impact guard assembly 12, includes a horizontalbumper 130 as well as two vertical bumper support members 72. Further,illustratively, the rear impact guard 12 may include two additionalbumper support members 70, as shown in FIG. 2, for example. As shown inFIG. 2, the additional bumper support members 70 are provided outsidethe two inner vertical bumper support members 72. As such, the outervertical bumper support members 72 are positioned at a location outsidethe slide rails 36. Accordingly, the rear impact guard 12 shown in FIG.2 includes right and left pairs of spaced-apart vertical bumper supportmembers 70, 72 such that the illustrative rear impact guard 12 of FIG. 2includes four vertical bumper support members. Each pair of verticalbumper support member includes an outermost vertical bumper supportmember 70 and an innermost vertical bumper support member 72.Illustratively, the outermost vertical bumper support member 70 mayprovide offset impact protection to vehicles in a rear-impact accidentwith the trailer 10. FIG. 2 illustrates both pairs of vertical supportbumper members 70, 72; however, only the innermost two vertical bumpersupport members are shown in FIG. 3 and described herein. As such, itshould be understood that the outermost two vertical bumper supportmembers 70 are identical in shape and function to the innermost verticalbumpers. It should be understood that while the rear impact guard 12 mayinclude two vertical bumper support members, as shown in FIGS. 1A and1B, as well as four vertical bumper support members as shown in FIG. 3,that it is within the scope of this disclosure for the rear impact guardto include any suitable number of vertical bumper support memberspositioned at any suitable location along the length of the horizontalbumper 130.

Illustratively, the outermost vertical bumper support member 70 ispositioned farther outward from a longitudinal centerline of the trailer10 than the innermost vertical bumper support member 72. In other words,the outermost vertical bumper support member 70 is closer to the nearestsidewall 16 of the trailer 10 than the innermost vertical bumper supportmember 72. As is discussed in greater detail below, such positioning ofthe inner and outermost vertical bumper support members 70, 72 providesthat each may be coupled to different portions of the bottom of thefloor assembly 14 of the trailer 10.

Because the outermost and innermost vertical bumper support members 70,72 are identical in structure, only the innermost vertical bumpersupport member 72 is described in detail herein. Like reference numeralsare used to denote like components of the inner and outer verticalsupport members 70, 72. Illustratively, the vertical bumper supportmember 72 includes two mirror-image shells 74, various views of a singleone of which is shown in FIGS. 5, 6, and 7. Illustratively, each shell74 is welded to one other mirror-image shell 74 to form a singlevertical bumper support member 72. Thus, each shell 74 is a generallyhollow component including angles, or corners, distributed to theoutside of the bumper support members 70, 72 thus providing increasedtorsional stability of the bumper support members 70, 72 while alsominimizing the overall weight of the rear impact guard 12. Reducing theweight of the rear impact guard operates to reduce the overall weight ofthe trailer thus allowing the operator to either increase the loadcapacity of the trailer and/or lower the fuel consumption by thetractor-trailer combination.

Each shell 74 includes a rear, vertical plate 76, a side plate 78, aswell as various flange members (described below) coupled to the sideplate 78. As shown in FIG. 5, the vertical plate 76 is rectangular inshape and includes three apertures 80 therethrough. The top-mostaperture 80 is provided to receive a fastener 170 therethrough in orderto couple the vertical bumper support member 72 to a mounting bracket160 which is then coupled to the rear door sill 54 of the trailer 10, asis discussed in greater detail below. The two lower apertures 80 areprovided to receive therethrough a bolt or other fastener in order toattach a rubber bumper (not shown), for example, to protect the verticalbumper support members 70, 72 in the event the bumper support members70, 72 impact a loading dock or other structure, for example. As shownin FIGS. 4 and 5, the side plate 78 is generally trapezoidal in shapeand includes a vertical member 82 coupled to one vertical edge 84 of thevertical plate 76, an upper horizontal member 86 coupled to an upper endof the vertical member 82 and configured to extend forwardly (relativeto the trailer 10) in a direction perpendicular to the vertical member82, and a lower horizontal member 87 coupled to a lower end of thevertical member 82 and similarly configured to extend forwardly in adirection perpendicular to the vertical member 82. An angled member 88of the side plate 78 extends between and is coupled to the forward endsof the upper and lower horizontal members 86, 77. As shown in FIG. 4, aportion of the angled member 88 extends below a lowermost-edge of thevertical plate 76 and the vertical member 82. An aperture 90 of the sideplate 78 is generally trapezoidal in shape and defined by the verticalmember, 82, upper horizontal member 86, lower horizontal member 87, andangled member 88 of the side plate 78.

Illustratively, while the side plate 78 is described above as beinggenerally trapezoidal in shape, it should also be understood that theside plate 78 is also generally triangular in shape and that the smalllower horizontal member 87 be considered as part of the vertical member82 and/or the angled member 88. In other words, it is within the scopeof this disclosure to consider the side plate 78 to be generallytriangular in shape and including the vertical member 82, the upperhorizontal member 86 and the angled member 88.

The shell 74 further includes a pair of flanges 92 coupled to a top edge93 of the upper horizontal member 86. The flanges 92 are spaced-apartfrom each other and configured to extend inwardly in a directionperpendicular to a plane defined by the upper horizontal member 86.Illustratively, the flanges 92 define a horizontal plane that isgenerally parallel to a plane defined by the floor boards 50 of thefloor assembly 14. As shown in FIG. 5, one of the flanges 92 includes anaperture 92 a formed therethrough. As is discussed in greater detailbelow, the aperture 92 a is configured to receive a fastener, such as abolt, to couple the vertical bumper support member 72 to the floorassembly 14 of the trailer 10.

The shell 74 further includes another flange 94 coupled to an outer edge95 of the angled member 88 of the side plate 78. As shown in FIGS. 4 and6, the flange 94 extends inwardly in a direction generally perpendicularto the angled member 88 and includes a flange plate 98 and three flangemembers 96 extending away from the flange plate 98 such that the flange94 is generally shaped like the number three when the shell 74 is viewedfrom a rear end as shown in FIG. 7. Finally, the shell 74 includes yetanother flange 100 extending inwardly from a lower, vertical edge 102 ofthe angled member 88. The flange 100 is perpendicular to the planedefined by the side plate 78 and includes an aperture 104 formedtherethrough.

As noted above, the vertical bumper support member 72 includes twomirror-image shells 74. The shells 74 are welded to one another along anouter edge 110 of each respective vertical plate 76, upper flanges 92,flange portions 96 of the angled flange plate 94, and bottom flange 100to form a central weld seam 120 (shown in FIGS. 1-3) along the edgeportions of each of the vertical plate 76 and the side plate 78. Asshown in FIG. 3, the edges 110 of the vertical plates 76 of each shell74 are welded together, and the edges 110 of the flanges 92, 96, 100 ofthe side plate 76 of each shell 74 are welded to each other to form asingle vertical bumper support member 70 and 72. While the illustrativeshells 74 of each vertical support bumper 70, 72 disclosed herein arewelded to each other along the edges 110 of each shell 74, it is withinthe scope of this disclosure the shells 74 to be coupled to each otherby other suitable fasteners, such as through the use of bolts, rivets,screws, and/or adhesives, for example. Further, while the illustrativevertical bumper support members 70, 72 are made of two separate shells74 which are coupled together, it is within the scope of this disclosurefor each vertical bumper support member 70, 72 to be made of any numberof components such that each vertical bumper support member 70, 72 mayinclude one, unitary component, or a plurality of separate componentsthat are coupled to each other using any suitable fastener or fasteningmeans.

Illustratively, the assembled vertical bumper support member 72 includestwo apertures 90 formed through the side plate 78 of each shell 74 ofthe bumper 72 as well as two apertures 122 formed between the adjoiningflange plates 94 of the shells 74. A cut-out portion 124, half of whichis shown by the shell 74 in FIG. 5, of the vertical bumper supportmember 72 is configured to receive the horizontal bumper 130. Thehorizontal bumper 130 is generally formed as a tube having a front wall140, a rear wall 142, a top wall 144, and a bottom wall 146. Inparticular, the front wall 140 and the bottom wall 146 are formed of asingle piece of steel having one bend formed therein to form an L-shapedmember, and the top wall 144 and the rear wall 142 are similar formed ofa single piece of steel having one bend formed therein to form anL-shaped member. Each L-shaped member is welded to each other L-shapedmember to form the horizontal bumper 130. As is stated above in regardto the vertical bumper support members 70, 72, the horizontal bumper 130may comprise one component or any number of components coupled to eachother by any suitable means including, for example, through the use ofrivets, screws, bolts, welds, and/or adhesives.

As noted above, the horizontal bumper 130 is received within the cut-outportion 124 of the vertical bumper support members 70, 72 such that abottom edge 150 of the vertical plate 76 and a common bottom edge 151 ofthe lower horizontal member 87 and the vertical member 82 of the sideplate 78 of each shell 74 are engaged with and rest upon the top wall144 of the horizontal bumper 130. Further, a rearwardly-facing surface152 of the flange 100 of each shell 74 is engaged with the front wall140 of the horizontal bumper 130. Illustratively, the horizontal bumper130 is welded and bolted to each of the two pairs of vertical bumpersupport members 70, 72. In particular, a bolt 131 (shown in FIG. 4) isreceived through an aperture (not shown) of the front wall 140 of thehorizontal bumper 130 and the aperture 104 of the flange 100 of eachshell 74 in order to further fasten horizontal bumper 130 to thevertical bumper support members 70, 72. While the vertical bumpersupport members 70, 72 are coupled to the horizontal bumper 130 in themanner described above, it is within the scope of this disclosure tocouple the horizontal bumper 130 and the vertical bumper support members70, 72 using other suitable fasteners including additional or fewerbolts, welding additional or fewer welds, rivets, screws, and/oradhesives, for example.

As shown in FIGS. 1 and 2, the vertical bumper support members 70, 72are coupled to the rear door sill 54 by mounting brackets 160.Illustratively, each mounting bracket 160 is generally U-shaped andincludes a front arm 162, a rear arm 164, and a center member 166coupled to and extending between each of the front and rear arms 162,164. As shown in FIGS. 1 and 2, the rear arm 164 is coupled to the upperportion of the adjoining vertical plates 76 of each vertical bumpersupport member 70, 72. Specifically, the rear arm 164 is coupled to thevertical plates 76 by a fastener, such as a bolt 170 received throughthe upper-most aperture 80 of each vertical plate 76 as well as twocorresponding apertures (not shown) of the mounting bracket 160. Thecenter member 166 is adjacent to and coupled with the adjacent,rear-most flanges 92 of each vertical bumper support member 70, 72 by afastener, such as a bolt (not shown) received through the aperture 94 ofeach flange 92 as well as through two corresponding apertures (notshown) of the center member 166 of the mounting bracket 160. The upperends of the front and rear arms 162, 164 of the mounting bracket 160 arewelded to the bottom surface of the base plate 60 of the sill 54.

As noted above, the rear impact guard 12 includes two pairs ofspaced-apart vertical bumper support members or brackets 70, 72 and ahorizontal bumper 130 which is mounted to the lower ends of the bumpersupport members or brackets 70, 72. The horizontal bumper 130 is formedas a closed end tube. The bumper 130 is secured to the lower ends ofbumper support members or brackets 70, 72 by suitable means, such aswelding. Illustratively, the spacing and placement of the verticalbumper support members 70, 72 or brackets 70, 72 with respect to eachother may be varied. In other words, the outer-most vertical bumpersupport members or brackets 70 may be moved inwardly or outwardlyrelative to the longitudinal axis of the trailer 10. Further, theinner-most vertical bumper support members 72 or brackets 72 may bemoved inwardly or outwardly relative to the longitudinal axis of thetrailer 10.

It should be understood that that while the particular rear impact guard12 shown in FIGS. 2-7 and described above includes two vertical bumpersupport members 70 and two vertical bumper support members 72, the rearimpact guard may be configured to only include two spaced-apart verticalsupport bumper support members 72, such as that shown in FIG. 1, forexample. Additionally, a rear impact guard 12 may be configured toinclude any number of vertical bumper support members 70 or 72.

Looking now to FIGS. 8-12, an alternative rear impact guard 212 isprovided. The rear impact guard 212 includes two spaced-apart verticalbumper support members 272, as shown in FIG. 12, and the horizontalbumper 130 coupled to each of the vertical bumper support member 272.Because the vertical bumper support members 272 are identical instructure, only one of the vertical bumper support members 272 isdescribed in detail herein. Like reference numerals are used to denotelike components of the two vertical support members 272. It should beunderstood that while the particular rear impact guard 212 includes twovertical bumper members 272, the rear impact guard may be configured toinclude any suitable number of vertical bumper support members 272. Forexample, the rear impact guard 212 may be configured to include twoadditional vertical bumper support members 272 located generally at theouter ends of the horizontal bumper 130 such that the rear impact guard212 includes a total of four vertical bumper support members 272. Asnoted above in regard to the rear impact guard 12, the vertical bumpersupport member or members 272 may be located at any suitable position orpositions along the length of the bumper 130.

Illustratively, the vertical bumper support member 272 includes twomirror-image shells 274 (shown in FIG. 10) and a center member 275coupled to the shells 274. Illustratively, each shell 274 is welded toone other mirror-image shell 274 and the center member 275 is positionedbetween and welded to the two shells 274 to form a single verticalbumper support member 70. Each shell 274 includes a rear, vertical plate276 and a side plate 278 coupled to the vertical plate 276. As shown inFIG. 10, the vertical plate 276 is rectangular in shape and includesthree apertures 280 therethrough. Similar to the apertures 80 describedabove with regard to the vertical bumper support member 72, the upperaperture 280 is provided to bolt the bumper support member 272 to thefloor assembly 14 of the trailer 10 while the two lower apertures 280are provided to receive therethrough a bolt or other fastener in orderto attach a rubber bumper (not shown), for example, to protect thebumper members 272, 272 in the event the bumper members 272, 272 impacta loading dock or other structure, for example. The side plate 278 isgenerally triangular in shape and includes a vertical member 282 coupledto one vertical edge 284 of the vertical plate 276, an upper horizontalmember 286 coupled to an upper end portion of the vertical member 282and configured to extend forwardly (relative to the trailer 10) in adirection generally perpendicular to the vertical member 282, and anangled member 288 of the side plate 278 extending between and coupled tothe forward ends of the upper horizontal member 286 and the verticalmember 282. A notch 279 is formed between the angled member 288 and thevertical member 282. As shown in FIG. 10, an aperture 290 of the sideplate 278 is generally triangular in shape and defined by the verticalmember 282, the upper horizontal member 286, and the angled member 288of the side plate 278.

Illustratively, an angle 292 (shown in FIGS. 8 and 10) between thevertical plate 276 and the vertical member 282 is approximately 87degrees. Thus, the side plate 278 is not perpendicular to the verticalplate 276, but rather angles slightly inwardly such that when the twoidentical shells 274 are coupled together, as shown in FIG. 8, adistance 289 between a forward-most end of the side plates 278 issmaller than a distance 291 between a rearward-most end of the sideplates 278. In particular, the distance 289 is approximately 4 incheswhile the distance 291 is approximately 6 inches. It should beunderstood that while the angle 292 is approximately 87 degrees, theshell 274 may define any suitable angle between the vertical plate 276and the vertical member 282 that is less than 90 degrees, equal to 90degrees, or greater than 90 degrees.

The vertical bumper support member 272 or bumper bracket 272 furtherincludes a center member 275, shown in FIGS. 8 and 11, coupled to eachshell 274. The center member 275 includes an upper, horizontal member302 and a lower member 304. An illustrative angle 306 between the uppermember 302 and the lower member 304 is approximately 48 degrees.However, it should be understood that any suitable angle may be used.The angle member 275 is illustratively a one-piece member; however, itis within the scope of this disclosure for the angle member 275 to bemade of more than one component.

The upper member 302 includes two apertures 308 configured to receive afastener therethrough in order to couple the vertical bumper supportmember 272 to the undercarriage of the floor assembly 14 of the trailer10. The apertures 308 are configured to each receive a fastener, such asa bolt (not shown) to couple the vertical bumper support member 272 tothe floor assembly 14. A mounting bracket (not shown) the same as orsimilar to the mounting bracket 160 described above in regard to therear impact guard 12 may be used to couple the vertical bumper supportmembers 272 to the undercarriage of the floor assembly 14 in the same orsimilar manner as that described above in regard to the vertical bumpersupport members 70 and 72. The lower member 304 includes an elongatedaperture 310. The aperture 310 operates to lessen the amount of materialused to manufacture the vertical bumper support member 272, thusminimizing the overall weight of the member 272. The aperture 310 mayalso operate as a drainage holes for the bumper support member 272 whenthe member 272 is painted and/or galvanized via a hot, as is discussedin. For example, when the bumper support member 272 is painted and/orgalvanized via a hot-dip galvanization process, the paint or molten zincbath into which the bumper support member 272 may be submerged isallowed to drain from between the shells 274 and center member 275 viathe aperture 310, as is described in greater detail below. The lowermember 304 includes a central body 303 and side flanges 312 coupled tothe central body 303 and oriented at approximately a 90 degree angle toan inner surface 314 of the lower member 304 and oriented in a forwarddirection. The side flanges 312 operate to provide additional strengthto the lower member 304 to help prevent the lower member 304 frombuckling under compression.

As shown in FIG. 8, the center member 275 is generally located betweenthe two shells 274 of the vertical bumper support member 272 such thatan outer edge 320 of the angled member 288 of the shell 274 is weldedthe inner surface 314 of the lower member 304 of the center member 275.Further an upper edge 322 of the side member 278 of the shell 274 isalso welded to the upper member 302 of the angle member 275 such thatthe forward-most portion of the edge 322 is welded to a bottom surface324 of the upper member 302 while the rearward-most portion of the edge322 (adjacent the vertical member 276 of the shell 274) is welded to anouter edge 326 of the upper member 302. As shown in FIG. 8, theforward-most portion of the side member 278 is located inward of theouter edges 326 of the upper member 302 due to the angle 292 between thevertical member 276 and the side member 278 being less than 90 degrees.Illustratively, as noted above, the distance 289 between theforward-most ends of the horizontal member 286 of the shells 274 of eachvertical bumper bracket 272 or bumper support member 272 isapproximately 4 inches while a distance 293 between the outer edges 326of the upper member 302 is approximately equal to the distance 291, or 6inches. The shells 274 are also welded to each other along a verticaledge 330 of the vertical member 276 of each shell 274 in order to createa center weld seam 320 between the edges 330 of the vertical plate 276of each shell 274. It should be noted that while the center member 275is welded to the shells 274 of the vertical bumper support member 272 orbumper bracket 272 and the shells 274 of each vertical bumper supportmember 272 or bumper bracket 272 are welded to each other, thesecomponents may be coupled to each other by other suitable meansincluding through the use of adhesives as well as various mechanicalfasteners such as rivets, bolts, screws, etc. Further, as is discussedin greater detail below, while the illustrative vertical bumper supportmembers 272 are made of two separate shells 274 and a center member 275which are coupled together, it is within the scope of this disclosurefor each vertical bumper support member 272 to be made of any number ofcomponents such that each vertical bumper support member 272 may includeone unitary component, or a plurality of separate component that arecoupled to each other using any suitable fastener or fastening means.

Illustratively, as shown in FIG. 12, the vertical bumper support members272 are coupled to the top and front members 144, 140 of the horizontalbumper 130 similar to the manner in which the vertical bumper supportmembers 70, 72 are coupled to the horizontal bumper 130. In particular,a bottom edge 250 of the vertical plate 282 and a bottom edge 251 of thevertical member 282 of the side plate 278 of each shell 274 are engagedwith and rest upon the top wall 144 of the horizontal bumper 130.Illustratively, the horizontal bumper 130 is welded to each bumpersupport member 272 along the bottom edges 250, 251 of the shells 274 ofeach member 272. A bottom edge 253 of the center member 275 is welded tothe front wall 140 of the horizontal bumper 130. While the verticalbumper support members 272 are each coupled o the horizontal bumper 130in the manner described above, it is within the scope of this disclosureto couple the horizontal bumper 130 and the vertical bumper supportmembers 272 to each other using other suitable fasteners including theuse of bolts, additional or few welds, rivets screws, and/or adhesives,for example.

Looking now to FIG. 13, an alternative vertical bumper support member372 is provided. Illustratively, the vertical bumper support member 372is similar to the vertical bumper support members 272 described above.Thus, like references numerals are used to denote like components.Further, the vertical bumper support member 372 is coupled to both thefloor assembly 14 of the trailer as well as to the horizontal bumper 130in the same or similar manner as that described above in regard to thevertical bumper support members 272.

Different from the vertical bumper support member 272, each shell 274 ofthe illustrative vertical bumper support member 372 includes two uppercut-outs 371 formed along the upper edge 322 of the side plate 278.Further, each shell 274 of the bumper support member 372 of FIG. 13includes two notches 374 along the outer edge 320 of the angled member288 of the side plate 278. Illustratively, the notches 371, 374 operateto provide drainage holes of the bumper support member 372. For example,when the bumper support member 372 is painted and/or galvanized via ahot-dip galvanization process, the paint or molten zinc bath into whichthe bumper support member 372 may be submerged is allowed to drain frombetween the shells 274 and center member 275 via the notches 371, 374once the bumper support member 372 is removed from the bath. The notch279 provides further access for drainage of any liquid material intowhich the bumper support member 372 may be submerged. The upper-mostapertures 280 of the vertical plate 276 of each shell 274 may be used toreceive a hanger or hook (not shown) after the bumper support member 372is painted and/or galvanized in order to allow the excess paint and/orliquid zinc to drain from the bumper support member 372.

Illustratively, the notches 371 and 374 may also operate as a visualindicator during the welding process. In particular, the notches 374provide an indicator to the welder as to where to start and stop weldingwhen welding the outer edge 320 of each shell 274 to the center member275. Similarly, the notches 371 provide a visual indicator to the welderas to where to start and stop welding when welding the upper edge 322 ofeach shell 274 to the center member 275.

Illustratively, the bumper support members 272, 372 are each made of twoshells 274 and the center member 275 positioned between and coupled toeach of the two shells 274. Thus, the bumper support members 272, 372each include three main components. Further, the bumper support members70, 72 are each made of two shells 74 thus including two maincomponents. However, as noted above, the bumper support members 70, 72,272, 372 disclosed herein may be made of any number of suitablecomponents that are bent and/or configured into the shapes shown anddescribed above. For example, as shown in FIGS. 14 and 15, a generallyplanar first component 400 and a generally planar second component 402are provided. The first component 400 includes many of the same orsimilar features of the shells 274 described above such that the firstcomponent 400 may be bent or folded along the two fold lines shown inFIG. 14 in order to form a one-piece structure that is equivalent to twoshells 274 coupled to each other. In other words, the two shells 274 ofthe bumper support member 272 may be formed from the single component400. A single vertical plate 476 between the fold lines 410 of the firstcomponent 400 is generally the same size and shape as the portion of thebumper support member 272 formed by coupling the vertical plate 276 ofeach shell 274 together. Forming the two shells 274 of the singlecomponent 400 may provide a stronger vertical bumper support memberbecause the weld seam 220, 320 is eliminated.

The second planar component 402, shown in FIG. 15, may be bent along thefold line 412 in order to form the center member 275 of the bumpersupport members 272, 372. Bending the second planar component 402 alongthe fold lines 414 operates to differentiate the central body 303 andthe flanges 312 of the lower member 304. Illustratively, the planarcomponents 400, 402 may be bent along the respective fold lines 410, 412by a progressive die machine or a stamping press, for example. As notedabove, it should be understood that while the vertical bumper supportmembers 272, 372 may be configured from the two planar components 400,402 shown in FIGS. 14 and 15, the vertical bumper support members 272,372 may also be formed from a single planar component (not shown) thatis able to be bent and configured to form the vertical bumper supportmembers 272, 372. Similarly, the vertical bumper support members 70, 72may be formed from a single planar component (not shown) that is able tobe bent and configured to form the vertical bumper support members 70,72 or bumper support brackets 70, 72.

Illustratively, the vertical bumper support members 70, 72, 272, 372,970, 974 or brackets 70, 72, 272, 372, 970, 974 disclosed herein aremade from advanced high strength steel such as, but not limited to,DOMEX® hot-rolled steel from SSAB Tunnplat in Sweden. In particular,thin steel sheets (i.e., approximately 3 millimeters) of advanced highstrength steel are used to fabricate the above described components ofthe vertical bumper support members or brackets 70, 72, 272, 372, 970,974. Further, the horizontal bumper 130 may also be made of the sameadvanced high strength steel. However, it should be understood that eachcomponent of the rear impact guards described herein may be made fromany suitable material including high strength steel, metals, metalalloys, plastics, and/or composites.

Illustratively, various bumper support members 70, 72, 272, 372, 970,974 are shown and described herein. As noted herein, each of thesebumper support members 70, 72, 272, 372, 970, 974 includes variouscomponents which cooperate to define a hollow, generally triangularprism. The hollow prism shape of each bumper support member 70, 72, 272,372, 970, 974 operates to increase bending and torsional strength of thebumper support member while also minimizing the amount of material usedto manufacture each member, thus minimizing weight and material cost ofeach member. The hollow prism includes first and second generallytriangle-shaped faces that are spaced-apart from each other as well asfirst, second, and third sides that are each positioned between andcoupled to the first and second triangle-shaped faces. Illustratively,the side plates 78, 278 of the bumper support members 70, 72, 272, 372define the first and second spaced-apart generally triangle-shapedfaces. The two adjacent vertical plates 76, 276 that are welded togetheras well as the single vertical plate 476 of the component 400 shown inFIG. 14 define the first side of the prism. The flanges 92 of two shells74 that are welded together define the second side of the prism whilethe horizontal member 302 of the center member 275 of the bumper supportmembers 272, 372 define the second side of the prism. The flanges 96 oftwo shells of the bumper support members 70, 72 that are welded togetherdefine the third side of the prism while the lower member 304 of thecenter member 275 of the bumper support members 272, 372 also define thethird side of the prism. The prism is illustratively a right-triangleprism such that the first side and the second side are generallyperpendicular to each other.

Looking now to FIGS. 16-20, an alternative rear impact guard 512 isprovided. As with the other rear impact guard embodiments disclosedherein, the rear impact guard 512 is configured to be coupled to anddepend downwardly from the bottom of the rear frame, such as rear frame18, and the rear end of a portion of the floor assembly, such as floorassembly 14, of a trailer the same as or similar to the portion oftrailer 10 shown in FIG. 1A. The rear impact guard 512 includes a rightand left vertical bumper support member 372 that are each the same as orsimilar to the vertical bumper support member shown in FIG. 13 and madefrom the first planar component 400 shown in FIG. 14 and the secondplanar component 402 shown in FIG. 15. As such, like reference numeralsare used to denote like components. The rear impact guard 512 furtherincludes a gusset 516 coupled to each of the right and left verticalbumper support members 372. Each gusset 516 is coupled to an outsideportion of the lower member 304 of the center member 275 of therespective vertical bumper support member 372. Illustratively, as shownin FIGS. 21-23, each gusset 516 generally defines a Z-shape when viewedfrom above, as shown in FIG. 23, and includes a triangular wall 518, amiddle wall 520 coupled to the triangular wall 518. Illustratively, thetriangular wall 518 defines a right-sided triangle. The triangular wall518 may be solid, as shown in FIGS. 21, 22, 24, and 25, for example, ormay include an aperture 570, as shown in FIGS. 16-20, in order to reducethe overall weight of the gusset 516.

The middle wall 520 is coupled to and extends along a hypotenuse edge523 of the triangular wall 518 and defines a shape similar to aparallelogram whereby the long sides of the middle wall 520 are parallelto each other but the short sides of middle wall 520 are not. Inparticular, the bottom, short side 521 of the middle wall 520 extendsfurther downwardly below a bottom side of the triangular wall 518. Eachgusset 516 further includes an end wall 522 coupled to the middle wall520 and extending along one side of the middle wall 520. The end wall522 defines a parallelogram. Illustratively, as shown in FIG. 23, afirst angle 530 between the triangular wall 518 and the middle wall 520is approximately 90 degrees while a second angle 532 between the middlewall 520 and the end wall 522 is similarly approximately 90 degrees. Thegusset 516 further includes notches 534 at the top and bottom of thegusset 516 between the triangular wall 518 and the middle wall 520.

The gusset 516 is illustratively formed from a planar component 550shown in FIG. 22. The planar component 550 is bent or folded along thetwo, parallel fold lines 552 shown in FIG. 22 in order to form theone-piece gusset 516. Illustratively, the planar component 550 may bebent along the fold lines 552 by a progressive die machine or a stampingpress, for example. As shown in FIG. 23 and described above, the planarcomponent 550 is bent along the parallel fold lines 552 to define the 90degree angles 530, 532 between the triangular wall 518, middle wall 520,and end wall 522 of the gusset 516. Illustratively, as described above,the gusset 516 is a one-piece, or unitary, component. However, thegusset 516 may be formed to include any number of separate componentsthat are coupled together to form or define the gusset 516.

As shown in FIG. 16-20, each gusset 516 of the rear impact guard 512 iscoupled to one of the vertical bumper support members 372. Specifically,an outer, vertical edge 560 of the gusset 516 is welded to an outerflange 562 of the center member 275. Illustratively, the outer flanges562 of the central member 276 are similar to the side flanges 312 of thecentral member 275 shown in FIG. 11; however, the outer flanges 562 areplanar with the central body 303 of the lower member 304 of the centermember 275 and are not bent 90 degrees as the side flanges 312 shown inFIG. 11. As such the outer-most outer flange 562 of each vertical bumpersupport member 372 is coupled to the vertical edge 560 of the gusset516. As shown best in FIG. 20, a bottom edge 563 of the triangular wall518 of the gusset 516 is generally aligned with a bottom edge 253 of thecenter member 275 and is also welded to the front wall 140 of thehorizontal bumper 130. The middle wall 520 and end wall 522 of thegusset 516 extend downwardly over the front face 140 of the horizontalbumper 130, as shown in FIG. 20 and are also welded to the front face140 of the bumper 130. As shown in FIG. 20, the bottom edge 582 of theend wall 522 is positioned approximately mid-way along a height of thefront face 140 of the bumper 130. In other words, the bottom edge 582 ofthe gusset 516 is positioned upwardly of the edge between the front face140 and the bottom face 146 of the horizontal bumper 130 to form astandard leg 527 of the gusset 516.

Alternatively, as shown in FIG. 26, the gusset 516 includes analternative middle wall 620 and an alternative end wall 622 such that abottom edge 682 of the outer wall 622 is positioned at the bottom edgeof the front face 140 of the horizontal bumper 130. Accordingly, abottom edge 621 of the middle wall 620 is longer than the bottom edge521 of the gusset 516 shown in FIG. 20, for example, in order to definean extended leg 627 of the gusset 516. It should be understood that thegusset 516 may be formed and configured such that the bottom edge of theend wall 522 of the gusset 516 is positioned at any height along thefront wall 140 of the horizontal bumper 130. Illustratively, the flange562 of the vertical bumper support member and the edge 560 of the gusset516 are welded to each other, while the other components of the gusset516 are welded to the horizontal bumper 130; however, it is within thescope of this disclosure to couple the gusset 516 and vertical bumpersupport member 372 to each other and to couple the gusset 516 to thebumper 130 using other suitable fasteners such as bolts, rivets, and/oradhesive in lieu of or in addition to one or more welds, for example.

Looking now to FIGS. 24, 25, and 33, a gusset attachment 600 is coupledto the gusset 516 of the rear impact guard 512. In particular, thegusset attachment 600 is coupled to a top edge 580 of the gusset 516 andengages and is coupled to a portion of the center member 275 of thevertical bumper support member 372. A bottom surface 602 of the gussetattachment 600 is welded to the top edge 580 of the gusset 516 in orderto generally close the open, Z-shape of the top edge 580 of the gusset516. Further, an inboard tip of the gusset attachment 600 rests againstthe planar surface of the central body 303 of the lower, angled member304 of the vertical bumper support member 372.

The gusset attachment 600 operates to further strengthen the gusset 516and vertical bumper support member 372 in the event of an impact by avehicle, for example. Particularly, the gusset attachment 600 mayprovide additional torsional strength to the rear impact guard 512. Asshown in FIG. 33, the gusset attachment 600 is a planar componentdefining five sides. Two pairs of opposite sides of the gussetattachment 600 are parallel to each other. In particular, sides 604 and606 are parallel to each other while sides 608 and 610 are parallel toeach other. Side 612 is not parallel to any other side of the gussetattachment 600. Illustratively, the gusset attachment 600 may alsodefine only four sides, as shown in FIGS. 27-29, for example.

Illustratively, the rear impact guard 512 may include the gussetattachment 600, or may be provided without the gusset attachment 600.

Looking now to FIGS. 27-29, a first and second cross-brace 700, 702 ofthe rear impact guard 512 is used with the vertical bumper supportmember 372, the gusset 516 (including the standard leg 527 shown in FIG.30 and the extended leg 627 shown in FIG. 27), the and the gussetattachment 600. The first and second cross-braces 700, 702 are eachcoupled at a respective first end 701, 703 to the vertical bumpersupport member 372 and at a respective second end 705, 707 to the gusset516. In particular, the first end 701, 703 of each of the first andsecond cross-braces 700, 702 is coupled to the lower member 303 of thecenter member 275 of the vertical bumper support member 372, and thesecond end 705, 707 of each of the first and second cross-braces 700,702 is coupled to the illustrative middle wall 620 of the gusset 516.The first and second cross-braces 700, 702 are welded to each of thegusset 516 and the vertical bumper support member 372, but may becoupled to the gusset 516 and the vertical bumper support member 372using other suitable fasteners including, but not limited to, rivets,screws, and/or adhesive, for example. The cross-braces 700, 702 operateto further strengthen the rear impact guard 512 against impact forcesfrom another vehicle.

As shown in FIG. 31, the first cross-brace 700 is illustratively formedfrom a planar component 750. The planar component 750 is bent, orfolded, along the parallel fold lines 752 to form the generally V-shapedfirst cross-brace 700. The planar component 750 and cross-brace 700include notches 754 for drainage of any fluids that may accumulate on oraround the component. As shown in FIG. 32, the second cross-brace 702 isformed from a planar component 850. The planar component 850 is bent, orfolded, along the parallel fold lines 852 to form the generally V-shapedsecond cross-brace 702. The planar component 850 and cross-brace 702also include notches 854 for drainage of any fluids. Illustratively, theplanar components 750, 850 may be bent along the respective fold lines752, 852 by a progressive die machine or a stamping press, for example.Illustratively, the cross-braces 700, 702 are each a one-piece, orunitary, components. However, the cross-braces 700, 702 may be formed toinclude any number of separate components that are coupled together toform or define the cross-braces 700, 702.

Illustratively, the rear impact guard 514 illustratively includes thevertical bumper support member 372 and the gusset 514 (having both thestandard and extended legs 527, 627). The rear impact guard 514 may alsoinclude the gusset attachment 600, the first cross-brace 700, and/or thesecond cross-brace 702. In other words, the gusset attachment 600 andcross-braces 700,702 may be used alone or in combination with each otherand with the gusset 514 and vertical bumper support member 372. Further,it should be understood that the gusset 514, gusset support 600, andfirst and second cross-braces 700, 702 shown and discussed in FIGS.16-33 may each be used, alone or in combination, with any of thevertical bumper support members shown and disclosed herein.

Referring now to FIGS. 34-44, further illustrative rear impact guards912, 1212 are depicted. Illustratively, each embodiment of truck 10disclosed herein generally comprises one of the embodiments of rearimpact guard 12, 212, 512, 912, 1212 also known as a rear impact guardassembly 12, 212, 512, 912, 1212, a floor assembly 14, and a trailerrear frame or end wall assembly 18, wherein like reference numerals areused to denote like components herein throughout. The rear impact guardassembly, the floor assembly and the rear frame assembly 18 are coupledtogether illustratively as described herein.

As further described herein, the floor assembly 14 generally comprises anumber of generally parallel cross members 38 and a number of generallyparallel slide rails 36, with the cross members 38 and slide rails 36being generally perpendicular to one another as illustrated for examplein FIGS. 1A, 1B, 34 and 41-44. Illustratively, the rails 36 and crossmembers 38 may be connected through any suitable means including usingfasteners, or they may be welded together. The floor assembly 14illustratively may further include an intercostal 47 extending betweenand generally perpendicular to adjacent cross members 38 to supportcross members 38 as seen for example in FIGS. 34 and 43. Eachintercostal 47 may be positioned between the upper horizontal flange 42and lower horizontal flange 44 of each respective cross member 38. Thecross members 38 may include end wall 48 to seal off one or both ends ofthe cross member 38.

Illustratively, an end clip 967 may be coupled together with and extendgenerally perpendicularly between one or both ends of two or more crossmembers 38. End clips 967 may be included at both ends of the two ormore adjacent cross members 38 (FIGS. 34 and 43) and may be positionedover end wall(s) 48. End clips 967 provide more stiffness for the floorassembly 14 to support the load input from the bumper support members970, 974, etc. during an impact. The inner portion of the cross members38 are similarly supported by the intercostals 47. In the illustrativeembodiment, end clips 967 are welded to end walls 48.

For example, as illustrated in FIGS. 34 and 41-43, three cross members38 are connected or coupled together with a pair of spaced apart endclips 967. Outer support bases 960 and inner support bases 961 underliein perpendicular relationship those three cross members. In addition anintercostal 47 extends between two of the cross members 38 and anotherintercostal 47 extends between two of the cross members 38.

As seen for example in FIGS. 34 and 41-44, outer support bases 960 andinner support bases 961 may be positioned such that the each supportbase 960, 961 extends or underlies on or more of the cross members 38.As seen in FIGS. 34, 36, 41 and 42 a pair of spaced apart outer supportbases 960 and a pair of spaced apart inner support bases 961 may beused. Support bases 960 and support bases 961 are spaced apart from eachother. In FIGS. 43 and 44, a plurality of spaced apart support bases 960illustratively are used.

As seen in FIG. 39, support base 960 generally comprises a continuousmember having at one end a generally upstanding front arm 964. The frontarm 964 and lower surface 966 are generally perpendicular to oneanother. Rear arm 962 extends at an angle generally upwardly and awayfrom lower surface 966. Illustratively, front arm 964 includes aplurality of apertures. Rear arm 962 illustratively includes aperture940. Lower surface 966 illustratively includes aperture 942. A generallyupside down U-shaped cover 969 is positioned between front arm 964 andrear arm 962, with the U-shaped opening of cover 969 facing downwardlytoward lower surface 966. Cover 969 illustratively includes aperture977. Cover 969 further includes notch 975.

As best seen in FIG. 40, support base 961 generally comprises acontinuous member having at one end a generally upstanding front arm965. The front arm 965 and lower surface 966 are generally perpendicularto one another. A rear arm 963 extends at an angle generally upwardlyand away from lower surface 966. Illustratively, front arm 965 includesa plurality of apertures. Rear arm 963 illustratively includes ordefines a cutout 968. Cutout 968 is formed to receive a portion of sliderail 36 as shown in FIGS. 41 and 42. Upright gusset 971 or wall 971 andupright gusset 972 or wall 972 are coupled with lower surface 966 in agenerally perpendicular relationship. Illustratively, walls 971, 972have a generally trapezoidal shape. While not shown in FIG. 40, supportbase also includes web member 973 as seen in FIG. 41. Illustratively,web member 973 makes a connection with slide rail 36 along the loweredge of the vertical wall of the component. Web member 973 has agenerally trapezoidal shape. It is sandwiched in an upright orientationbetween walls 971, 972. Web member 973 illustratively extends from frontarm along lower surface 966, through the gap between upright wall 971and upright wall 972 and up along rear arm 963. Illustratively, webmember 973 has a lower edge that may be attached together,illustratively for example by welding, with lower surface 966.Illustratively, web member 973 has a right upstanding edge that may beattached together, illustratively for example by welding, with frontface 965. Upper edge of web member 973 extends from the front face 965,through the gap between walls 971, 972 and intersects rear arm 963partially up rear arm 963.

Support bases 960, 961 are coupled to trailer rear frame 18 as shown inFIGS. 41 and 42. Illustratively, support bases 960, 961 are coupled tofantail 48. Upstanding front arms 964, 965 of support bases 960, 961 arecoupled with trailer rear frame 18. Illustratively, support bases 960,961 extend away from and are cantilevered from trailer rear frame 18. Insome embodiments, support bases 960, 961 are bolted or otherwisefastened with trailer rear frame 18. In other embodiments, support bases960, 961 are welded with trailer rear frame 18. In some embodiments,support bases 960, 961 are bolted, welded, or otherwise fastened withcross members 38 and or bumper support members 70, 74, 270, 970, 974,etc.

Rear assembly 18, also known as the rear frame 18 or end wall 18, as hasbeen described, may include rear frame 20 or end wall frame 20. Rearassembly 18 may further include elongated horizontal sill 54. Verticalposts 56 may extend upwardly from the opposite ends of sill 54. Asnoted, in some embodiments, extended posts 56 may replace rear frame 20.Rear assembly 18 may further include an elongated horizontal top member,i.e., rear door header, (not shown). Posts 56 illustratively areconnected to respective sidewalls 16 by rivets, but may be connected byany suitable fastener, weld, and/or adhesive. The opposite ends of sill54 are connected to respective base rails 40 by known welding, but maybe connected in any suitable manner. Illustratively, sill 54 includes afantail 58 and a base plate 60 attached to the underside of the fantail58.

Illustratively, as shown in FIGS. 34-42, rear impact guard assembly 912,includes horizontal bumper 130 as well as two vertical bumper supportmembers 970 and two vertical bumper support members 974. Each outervertical bumper support member 970 illustratively is positioned at alocation outside the slide rails 36. Each inner vertical bumper supportmember 974 is positioned inboard of each outer bumper support member970. Further illustratively, each inner bumper support member 974 ispositioned generally under and inboard of respective slide rails 36.Accordingly, the rear impact guard 912 shown in FIG. 34 includes rightand left pairs of spaced-apart vertical bumper support members 970, 974such that the illustrative rear impact guard 912 of FIG. 34 includesfour vertical bumper support members 970, 974.

Each pair of vertical bumper support member includes an outermostvertical bumper support member 970 and an innermost vertical bumpersupport member 974.

Illustratively, the outermost vertical bumper support member 970 mayprovide offset impact protection to vehicles in a rear-impact accidentwith the trailer 10. FIG. 34 illustrates both pairs of vertical supportbumper members 970, 974; however, only one pair of vertical bumpersupport members 970, 974 are shown in FIGS. 35-36 and 41-42 anddescribed herein. As such, it should be understood that the other pairof vertical bumper support members 970, 974 are identical in structureand function to the described vertical bumpers 970, 974.

It should be understood that while the rear impact guard 912 may includetwo pairs of vertical bumper support members 970, 974, as shown in FIG.34, it is within the scope of this disclosure for the rear impact guard912 to include any suitable number of vertical bumper support members970 or 974 or pairs of bumper support members 970 and 974 positioned atany suitable location along the length of the horizontal bumper 130. Forexample, as will be further described, rear impact guard assembly 1212(FIGS. 43-44) illustratively includes a plurality of vertical bumpersupport members 970. For example, FIGS. 43-44 illustratively disclosethree spaced apart bumper support members 970, which are eachillustratively spaced apart from slide rails 36.

Illustratively, each outermost vertical bumper support member 970 ispositioned farther outward from a longitudinal centerline of the trailer10 than each innermost vertical bumper support member 974. In otherwords, outermost vertical bumper support member(s) 970 is closer to thenearest sidewall 16 of the trailer 10 than innermost vertical bumpersupport member(s) 974. Such positioning of the inner and outermostvertical bumper support members 970, 974 provides that each may becoupled to different portions of the bottom of the floor assembly 14 ofthe trailer 10.

Illustratively, vertical bumper support members 970, 974 comprise agenerally hollow component including angles, or corners, distributed tothe outside of the bumper support members 970, 974 thus providingincreased torsional stability of the bumper support members 970, 974while also minimizing the overall weight of the rear impact guard 912.Reducing the weight of the rear impact guard operates to reduce theoverall weight of the trailer thus allowing the operator to eitherincrease the load capacity of the trailer and/or lower the fuelconsumption by the tractor-trailer combination.

Illustratively, bumper support member 970, 974 is generally triangularin shape. As noted above for bumper support members 70, 72, 272, 372,bumper support member 970, 974 may be made of any number of suitablecomponents that are bent and/or configured into the shapes shown anddescribed above. Bumper support member 970 includes vertical member 476or vertical plate 476 sandwiched between and generally perpendicular tospaced apart angle members 288. A center member 275 or angle member 275may be positioned between or over the spaced apart angle members 288.

Bumper support member 970 may be formed from planar component 1000,which is illustratively trapezoidal in shape (FIG. 37). Planar member1000 includes vertical member 476 with angled member 288 extending oneither side of vertical member 976. Planar member 1000 may be bent orfolded along the two fold lines 1010 shown in FIG. 37 in order to form aone-piece structure. Single vertical plate or member 476 located betweenthe fold lines 1010 is generally the same size and shape as the portionof the bumper support member 272 formed by coupling the vertical plate276 of each shell 274 together.

While the angle members 288 could be welded or otherwise connected tovertical member 976, forming the shell of bumper support member 970, 974from single planar component 1000 may provide a stronger vertical bumpersupport member. Planer component 1000 further includes apertures 378.Each aperture 378 is formed on each side of member 476. Planer component1000 further includes notches 376 formed along a lower portion of angledmember 288.

Bumper support member 974 may be formed from planar component 1100,which is illustratively trapezoidal in shape (FIG. 38). Planar member1100 includes vertical member 476 with angled member 988 extending oneither side of vertical member 476. Planar member 1100 may be bent orfolded along the two fold lines 1110 shown in FIG. 38 in order to form aone-piece structure. Single vertical plate or member 476 located betweenthe fold lines 1110 is generally the same size and shape as the portionof the bumper support member 272 formed by coupling the vertical plate276 of each shell 274 together. The planer component 1100 includes anupper horizontal member 986 and an angled member 988. The horizontalmember 986 is relatively shorter than horizontal member 286 to cause anangle of the angled member 988 to be smaller than the angle of theangled member 288.

While the angle members 988 could be welded or otherwise connected tovertical member 476, forming the shell of bumper support member 974 fromsingle planar component 1100 may provide a stronger vertical bumpersupport member. Planer component 1100 further includes apertures 378.Each aperture 378 is formed on each side of member 476. Illustratively,the apertures 378 of bumper support member 974 align with apertures ofbumper support members 970. Planer component 1100 further includesapertures 990. Planar components 1000, 1100 may be folded or bent asdescribed by a progressive die machine or a stamping press, for example.As noted above, it should be understood that while the vertical bumpersupport members 970, 974 may be configured from planar components 1000,1100 and center member 275, the vertical bumper support members 970, 974may also be formed from a single planar component (not shown) that isable to be bent and configured to form the vertical bumper supportmembers 970, 974.

A rear impact guard 1212 is shown in FIGS. 43 and 44. Rear impact guard1212 includes three bumper support members 970 and three support bases960. The three bumper support members 970 are spaced apart aboutequidistant from one another. One of the bumper support members 970 islocated about midway along horizontal bumper 130. Rear impact guard 1212further includes center member 277. Center member 277 is substantiallysimilar to center member 275. However, an upper member 305 of centermember 277 is relatively shorter than upper member 302 of center member275.

In the illustrative embodiment, bumper support members 70, 74, 270, 272,372, 970, 974, etc. and horizontal bumper 30 comprise high strengthsteel. Illustratively, The floor assembly 14 and the support bases 960,961 comprise 50K or 80K steel. In other embodiments, any number ofcomponents may comprise high strength steel or any other suitablematerial.

The floor assembly 14 is bolted or fastened to the rear frame 18 in theillustrative embodiment. Illustratively, rear impact guard 912, 1212 arebolted or fastened to the rear frame 18. The rear impact guard 912, 1212and the floor assembly are not directly connected, in the illustrativeembodiment, but the support bases 960, 961 transmit loads when the rearimpact guard 912, 1212, etc. apply a force to the support bases 960,961, for example, during an impact event. In some embodiments, thebumper support members 70, 72, 970, 974, etc. are spaced apart so that acar cannot collide with the rear impact guard 12, 912, 1212, etc.without colliding with at least one bumper support member 70, 72, 970,974, etc. In some embodiments, the bumper support members 70, 72, 970,974, etc. are positioned about three inches inward from the widestportion of the trailer 10.

Vertical bumper support member 970, as shown in FIGS. 34-36 and 42-44,may be welded, bolted, or otherwise fastened with bumper 130 and rearframe 18. The rear frame assembly 18 includes the rear frame 20 whichforms a rectangular opening into which the rear door or doors (notshown) are provided. As noted above, the rear impact guard 12, 912,1212, etc. may be coupled to the rear end wall and underside of thefloor assembly 14 of the trailer 10. In particular, the rear impactguard 12, 912, 1212 may be coupled to the base plate 60 of the rear sill54 and to the slide rails 36 of the trailer 10.

In another embodiment, a rear impact guard 1412 includes horizontalbumper 1430, bumper support members 1470,1474, and bumper mounts 1471,as shown in FIGS. 45, 46. The rear impact guard 1412 can be coupled tothe floor assembly 14 of the trailer 10 in a similar manner to the rearimpact guards 12, 212, 512, 912, 1212, and may additionally includeinner support bases 960 and outer support bases 961. The rear impactguard 1412 may improve safety in the event of a collision.

The bumper support members 1470, 1474 include two outer bumper supportmembers 1470 and two inner bumper support members 1474, as shown inFIGS. 45, 46. Outer bumper support members 1470 are similar inconstruction and function to outer bumper support members 970, and innerbumper support members 1474 are similar in construction and function tothe inner bumpers support members 974. The two inner bumper supportmembers 1474 are located between the two outer bumper support members1470 when viewing the trailer 10 from the rear. The inner bumper supportmembers 1474 and outer bumper support members 1470 extend downwardlyfrom the rear of the trailer and couple to the horizontal bumper 1430with the bumper mounts 1471.

Each of the bumper support members 1470, 1474 include a generallytriangular shaped prism member 1413, 1415, apertures 1475, and a basemount 1417, as shown in FIGS. 45, 46. The bumper support members 1470,1474 are configured to removably couple to the horizontal bumper 1430.The base mounts 1417 are located at the top end of the prism members1413, 1415 and are configured to couple the prism members 1413,1415 tothe support bases 960, 961 or support bases 1660, 1661, and to thetrailer 12. The bumper mounts 1471 are located between the base mounts1417 and the horizontal bumper 1430 within a generally hollow area ofthe prism members 1413, 1415. In an embodiment, the bumper mount 1471 isconfigured to allow the horizontal bumper 1430 to be removed from therear impact guard 1412 without removing the bumper support members 1470,1474 in the event that the horizontal bumper 1430 needs replaced. In anembodiment, each bumper support member 1470,1474 includes threeapertures 1475, although two or any number of apertures may be suitable.

The bumper mounts 1471 include a bracket 1477, a bracket receiver 1473,and three apertures 1479 as shown in FIG. 46. The bracket 1477 ispermanently mounted on the horizontal bumper 1430 and configured to movetherewith as shown in FIG. 46. The bracket receiver 1473 is locatedwithin the hollow interior space of the triangular prism members 1413,1415 and is configured to receive the bracket 1477. The three apertures1479 are located on the bracket 1477 and are configured to receive afastener 1486 therethrough. The apertures 1479 are configured to overliewith the apertures 1475 of the triangular prism member 1413,1415 toreceive a fastener 1486 therethrough and removably couple the horizontalbumper 1430 to the bumper support members 1470, 1474. In an embodiment,the fastener 1486 is a bolt 1489 and a nut 1491, although the fastenercan be any other suitable fastening means such as a rivets, pins, orscrews. Alternatively, the brackets 1477 may couple to the exterior ofthe bumper support members 1470, 1474. In an embodiment, the bracket1477 is comprised of steel and is coupled to the horizontal bumper 1430with a weld.

Illustratively, the bracket 1477 is c-shaped and includes a rear face1481 and two side faces 1483, as shown in FIGS. 45, 46. The rear face1481 can have a width greater than a width of the two side faces 1483,or can have the same width. The rear face 1481 faces in a rearwarddirection from the trailer 10. The side faces 1483 couple to the rearface 1481 at a generally perpendicular angle to the rear face 1481 andare generally parallel to the sidewalls 16 of the trailer 10. The rearface 1481 and the side faces 1483 each include an aperture 1479configured to receive the fastener 1486 therethrough.

In another embodiment, a rear impact guard 1612 includes a horizontalbumper 1630, bumper supports 1670,1674, and bumper mounts 1671, as shownin FIGS. 47-52. The rear impact guard 1612 can be coupled to the floorassembly 14 of the trailer 10 in a similar manner to the rear impactguards 12, 212, 512, 912, 1212, 1412 and may additionally include outersupport bases 1660 and inner support bases 1661. Alternatively, the rearimpact guard 1612 may use the support bases 960, 961. The rear impactguard 1612 may improve safety in the event of a collision.

The rear impact guard 1612 can include two outer support bases 1660, andtwo inner support bases 1661, as suggested in FIG. 47. Each outersupport base 1660 and inner support base 1661 is coupled to the floorassembly 14, as seen for example in FIG. 47. Outer support bases 1660may be positioned such that the outer support bases 1660 are locatedbetween the sidewalls 16 and the inner support bases 1661, and eachinner support base 1661 is located in spaced-apart relation within thetwo outer support bases 1660 and along the floor assembly 14. Eachsupport base 1660, 1661 extends or underlies on one or more of the crossmembers 38. In an embodiment, the support bases 1660 are positionedbetween the bumper support member 1670, 1674 and the floor assembly 14such that a slight gap exists between the support bases 1660, 1661.

Outer support base 1660 includes a continuous plate having at one end agenerally upstanding front arm 1664, lower surface 1629 extending fromfront arm 1664 to a rear arm 1662, a top plate 1669, and a web 1620, asseen in FIG. 48. In an embodiment the outer support base 1660 does notinclude the top plate 1669. The front arm 1664 and lower surface 1629are generally perpendicular to one another. In an embodiment, rear arm1662, lower surface 1629, and front arm 1664 are all made of a singlepiece. In another embodiment the top plate 1669 is coupled to the web1620. Rear arm 1662 extends at an angle generally upwardly and away fromlower surface 1629. Illustratively, front arm 1664 can include aplurality of apertures 1627. In an embodiment, outer support base 1660is comprised of steel, or high strength steel.

The web 1620 extends vertically between lower surface 1629 and top plate1669, as seen in FIG. 48. In another embodiment without the top plate1669, the web 1620 extends vertically from the lower surface 1629 at agenerally perpendicular angle to the lower surface 1629. Web 1620 has agenerally trapezoidal shape and is generally perpendicular to the lowersurface 1629 and the front arm 1664. Web 1620 illustratively extends inthe horizontal direction along lower surface 1629 between front arm 1664to rear arm 1662. Illustratively, web 1620 may be coupled, for exampleby welding, with lower surface 1629 or with front arm 1664, or ifpresent, top plate 1669.

In an embodiment, outer support base 1660 also includes the generallytriangular gussets 1622, 1623 for additional stiffness, as seen in FIG.48. Triangular gussets 1622, 1623 extend in a vertical direction alongthe web 1620 from the lower surface 1629 to the top plate 1669.Triangular gussets 1622 are generally in the same plane on opposingsides of the web 1620, an and may be coupled to the top plate 1669.Illustratively, outer support base 1660 includes two generallytriangular gussets 1622, 1623, however any number of additional gussetscan be used to further strengthen outer support base 1660.

Inner support base 1661 includes a continuous plate having at one end agenerally upstanding front arm 1666, lower surface 1626 extending fromfront arm 1666 to rear arms 1632, 1668, and a web 1621, as seen in FIG.49. The front arm 1666 and lower surface 1626 are generallyperpendicular to one another. In an embodiment, rear arms 1632,1668,lower surface 1626, and front arm 1666 are all made of a single piece.Rear arms 1632,1668 extend at an angle generally upwardly and away fromlower surface 1626. Illustratively, front arm 1666 can include aplurality of apertures 1628. In an embodiment, inner support base 1661is comprised of steel, or high strength steel.

The web 1621 extends vertically from lower surface 1626, as seen in FIG.49. Web 1621 has a generally trapezoidal shape and is generallyperpendicular to the lower surface 1626 and the front arm 1666. Web 1621illustratively extends in the horizontal direction along lower surface1626 between front arm 1666 to rear arms 1632, 1668. Illustratively, web1621 may be coupled, for example by welding, with lower surface 1626 orwith front arm 1666.

The rear arms 1632, 1668 extend at an angle from the lower surface 1626towards the floor assembly 14 of the trailer 10. In an embodiment, reararm 1668 is formed to receive a portion of slide rail 36, as shown inFIG. 49, and has a generally shorter length than the length of rear arm1668.

In an embodiment, inner support base 1661 also includes the generallyrectangular gussets 1624, 1625 for additional stiffness, as seen in FIG.49. Rectangular gussets 1624, 1625 extend at an angle similar to therear arms 1668, 1621 1 along the web 1621 from the lower surface 1626.Rectangular gussets 1624, 1624 are generally in the same plane as eachother on opposing sides of the web 1621. In an embodiment, the length ofrectangular gusset 1624 is generally the same as the length of rear arm1668, as to receive a portion of the slide rail 36. Illustratively,inner support base 1661 includes two generally rectangular gussets 1624,1626, however any number of additional gussets can be used to furtherstrengthen inner support base 1661.

Support bases 1660, 1661 are coupled to trailer rear frame 18 as shownin FIG. 47. Illustratively, support bases 1660, 1661 are coupled tofantail 48. Upstanding front arms 1664, 1666 of support bases 1660, 1661are coupled with trailer rear frame 18. Illustratively, support bases1660, 1661 extend away from and are cantilevered from trailer rear frame18. In some embodiments, support bases 1660, 1661 are bolted orotherwise fastened with trailer rear frame 18. In other embodiments,support bases 1660, 1661 are welded with trailer rear frame 18. In stillother embodiments, for example, when utilizing a composite trailer floorassembly, supper bases 1660, 1661 may be laminated or otherwise bondedto the composite floor assembly. In some embodiments, support bases1660, 1661 are bolted, welded, or otherwise fastened with cross members38 and or bumper support members 70, 74, 270, 970, 974,1470, 1474, 1670,1674 or any other bumper support members.

The bumper support members 1670, 1674 include two outer bumper supportmembers 1670 and two inner bumper support members 1674, as shown inFIGS. 47, 51, 52. Outer bumper support members 1670 are similar inconstruction and function to outer bumper support members 970, and innerbumper support members 1674 are similar in construction and function tothe inner bumpers support members 974. The two inner bumper supportmembers 1674 are located between the two outer bumper support members1670 when viewing the trailer 10 from the rear. The inner bumper supportmembers 1674 and outer bumper support members 1670 extend downwardlyfrom the rear of the trailer and couple to the horizontal bumper 1630with the bumper mounts 1671.

Each of the bumper support members 1670, 1674 include a generallytriangular shaped prism member 1613, 1615, apertures 1675, and a basemount 1617, as shown in FIGS. 51, 52. The bumper support members 1670,1674 are configured to removably couple to the horizontal bumper 1630.The base mounts 1617 are located at the top end of the prism members1613, 1615 and are configured to couple the prism members 1613,1615 tothe support bases 960, 961 and to the trailer 12. The bumper mounts 1671are located between the base mounts 1617 and the horizontal bumper 1630within a generally hollow area of the prism members 1613, 1615. In anembodiment, the bumper mount 1671 is configured to allow the horizontalbumper 1630 to be removed from the rear impact guard 1612 withoutremoving the bumper support members 1670, 1674 in the event that thehorizontal bumper 1630 needs replaced. In an embodiment, each bumpersupport member 1670,1674 includes two apertures 1675, although anynumber of apertures may be suitable.

The bumper mounts 1671 include a bracket 1677, a bracket receiver 1673,and two apertures 1679, as shown in FIGS. 47, 51, 52. The bracket 1677is permanently mounted on the horizontal bumper 1630 and configured tomove therewith, as shown in FIG. 51. The bracket receiver 1673 islocated within the hollow interior space of the triangular prism members1613, 1615 and is configured to receive the bracket 1677. The twoapertures 1679 are located on the bracket 1677 and are configured toreceive a fastener 1686 therethrough. The apertures 1679 are configuredto overlie with the apertures 1675 of the triangular prism member1613,1615 to receive a fastener 1686 therethrough and removably couplethe horizontal bumper 1630 to the bumper support members 1670, 1674. Inan embodiment, the fastener 1686 is a bolt 1689 and a nut 1691, althoughthe fastener can be any other suitable fastening means such as a rivets,pins, or screws. Alternatively, the brackets 1677 may couple to theexterior of the bumper support members 1670, 1674. Illustratively, thebumper mounts 1671 are configured to offset the horizontal bumper 1630to extend the horizontal bumper 1630 in a rearward direction, so thatthe rear wall 1631 of the horizontal bumper 1630 is in the same plane asthe base plate 60, as shown in FIGS. 47, 52. Offsetting the horizontalbumper 1630 may ease the access to the interior of the trailer whenusing the horizontal bumper 1630 as a step. In an embodiment, thebracket 1677 is comprised of steel and is coupled to the horizontalbumper 1630 with a weld.

Illustratively, the bracket 1677 is c-shaped and includes a front panel1681, and two side panels 1663 as shown in FIGS. 51, 52. The front panel1681 is configured to overlap and face the front wall 1633 of thehorizontal bumper 1630. The two side panels 1683 are L-shaped, and havea first segment 1665 that extends the length of the front panel 1681 andcouple to the front wall 1633 of the horizontal bumper 1630. The sidepanels 1683 further include a second segment 1667 that couples to thetop wall 1635 of the horizontal bumper 1630 and includes the aperture1679. In an embodiment, the apertures 1679 of the bumper mount overlapwith the apertures 1675 of the triangular prism member 1613,1615 toreceive a fastener 1686 therethrough and couple the horizontal bumper1630 to the bumper support members 1670, 1674. In an embodiment, thefastener 1686 is a bolt 1689 and a nut 1691, although the fastener 1686can be any other suitable fastening means such as a rivets, pins, orscrews. Illustratively, the bracket 1677 is configured to couple to theinterior space 1685, 1687 of the triangular prism members 1613,1615 asshown in FIGS. 47, 52. Alternatively, the brackets 1677 could couple tothe exterior of the bumper support members 1670, 1674.

In an embodiment, the horizontal bumper 30, 130, 1430, 1630 can includea tube stiffener 1711 and a hollow tube 1713 as shown in FIGS. 53-57.While the horizontal bumper 1430 is shown illustratively, it should beunderstood that any horizontal bumper 30, 130, 1430, 1630 can includethe tube stiffener 1711. The tube stiffener 1711 is coupled to thehollow tube 1713 to prevent compaction of the horizontal bumper 1430upon impact in the event of a collision.

The tube stiffener 1711 includes a first flange mount 1715, a secondflange mount 1717 located in spaced-apart relation to the first flangemount 1715, and a web 1719 extending between the first flange mount 1715and the second flange mount 1717 as shown in FIG. 53. The web 1719 canillustratively be any length. For example, the web 1719 can be the samelength as the distance between the bumper supports 1470, 1474 or can belonger or shorter, depending on the rear impact guard 212, 512, 912,1212, 1412, 1612. Illustratively, the tube stiffener 1711 includes afirst flange mount 1715 and a second flange mount 1717, however, anynumber of flange mounts can be added to increase the stiffening of thetube. The tube stiffener 1711 is located within the hollow tube 1713 ateither end 1726, 1728, or both ends 1726, 1728 of the hollow tube belowthe bumper support members 1470, 1474 as shown in FIGS. 54-57. The tubestiffener 1711 is positioned so the web 1719 is in the same plane as theangled member 1468 of the triangular shaped prism member 1415, which mayimprove the load transfer during a collision. The tube stiffener 1711can be comprised of steel, high strength steel, or any other metallic orblock polymer material. In an embodiment, the thickness of tubestiffener 1711 can range from about 0.05 to about 0.3 inches, about 0.05to 0.2 inches, about 0.1 to about 0.3 inches, or alternatively, can beabout 0.1 inches thick, about 0.2 inches thick, or about 0.25 inchesthick.

The flange mounts 1715, 1717 are generally triangular and each include afirst edge 1725, a second edge 1727, a third edge 1729, and a web mount1730 as shown in FIGS. 53-57. Illustratively, the first edge 1725 andthe second edge 1727 each have a generally similar length which is lessthan the length of the third edge 1729. The third edge 1729 is coupledto the web 1719 along the web mount 1730 at a generally perpendicularangle so that the flange mounts 1715, 1717 are generally perpendicularto the web 1719.

In an embodiment, the flange mounts 1715, 1717 can be mounted to an endface 1721,1723 of the exterior of the hollow tube, as shown in FIGS. 54,55. Illustratively, the flange mounts 1715, 1717 can be coupled to thehollow tube 1713 so that the first edge 1725 couples to the end edge1737 of the top wall 1735 of the hollow tube 1713 and the second edge1727 couples to the end edge 1739 of the rear wall 1731 of the hollowtube 1713 so that web 1719 is in the same plane as the angled member1468 of the triangular shaped prism member 1415. Illustratively, if thetube stiffener 1711 is comprised of steel or high strength steel, andcan be coupled to the hollow tube 1713 by welding.

In another embodiment, the flange mounts 1715, 1717 can be mounted tothe interior of the hollow tube 1713 as shown in FIGS. 56, 57.Illustratively, the flange mounts 1715, 1717 can be coupled to thehollow tube 1713 so that the first edge 1725 couples to the top wall1735 of the hollow tube 1713 and the second edge 1727 couples to therear wall 1731 of the hollow tube 1713 so that web 1719 is in the sameplane as the angled member 1468 of the triangular shaped prism member1415. Illustratively, if the tube stiffener 1711 is comprised of steelor high strength steel, and can be coupled to the hollow tube 1713 bywelding.

In an embodiment, the horizontal bumper 30, 130, 1430, 1630 can includea tube stiffener 1811 and a hollow tube 1813 as shown in FIGS. 58-62.While the horizontal bumper 1430 is shown illustratively, it should beunderstood that any horizontal bumper 30, 130, 1430, 1630 can includethe tube stiffener 1811. The tube stiffener 1811 is coupled to thehollow tube 1813 to prevent compaction of the horizontal bumper 1430upon impact in the event of a collision.

The tube stiffener 1811 includes a first flange mount 1815, a secondflange mount 1817 located in spaced-apart relation to the first flangemount 1815, and a web 1819 extending between the first flange mount 1815and the second flange mount 1817 as shown in FIG. 58. The web 1819 canillustratively be any length. For example, the web 1819 can be the samelength as the distance between the bumper supports 1470, 1474 or can belonger or shorter, depending on the rear impact guard 212, 512, 912,1212, 1412, 1612. Illustratively, the tube stiffener 1811 includes afirst flange mount 1815 and a second flange mount 1817, however, anynumber of flange mounts can be added to increase the stiffening of thetube. The tube stiffener 1811 may be located within the hollow tube 1813at either end 1821, 1823, or at both ends 1821, 1823 of the hollow tube1813 below the bumper support members 1470, 1474 as shown in FIGS.59-62. The tube stiffener 1811 is positioned so the web 1819 is in thesame plane as the angled member 1468 of the triangular shaped prismmember 1415 which may improve the load transfer during a collision. Thetube stiffener 1811 may be comprised of steel, high strength steel, orany other metallic or block polymer material. In an embodiment, thethickness of tube stiffener 1811 can range from about 0.05 to about 0.3inches, about 0.05 to 0.2 inches, about 0.1 to about 0.3 inches, oralternatively, can be about 0.1 inches thick, about 0.2 inches thick, orabout 0.25 inches thick.

The flange mounts 1815, 1817 include a generally triangular wing 1824,1826, a web mount 1833, and a generally triangular gusset 1832, 1834, asshown in FIG. 58. The triangular wings 1824, 1826 and the triangulargussets 1832, 1834 generally lie in the same plane and are mounted tothe web 1819 at a generally perpendicular angle. The flange mount 1815includes the wing 1824 and the gusset 1832 and is arranged to couple toan end 1821, 1823 of the hollow tube 1813 to stiffen the horizontalbumper 1830.

The triangular wings 1824, 1826 each include a first edge 1825, a secondedge 1827, and a third edge 1829, as shown in FIGS. 58-62.Illustratively, the first edge 1825 and the second edge 1827 each have agenerally similar length which is less than the length of the third edge1829. The third edge 1829 is coupled to the web 1819 along the web mount1833 at a generally right angle so that the triangular wings 1824, 1826are generally perpendicular to the web 1819.

The triangular gussets 1832, 1834 each include a first edge 1841, asecond edge 1843, and a third edge 1845, as shown in FIGS. 58-62.Illustratively, the first edge 1841 and the second edge 1843 each have agenerally similar length which is less than the length of the third edge1845. The third edge 1845 is coupled to the web 1819 at a generallyright angle so that the triangular gussets 1832, 1834 are generallyperpendicular to the web 1819. Illustratively, tube stiffener 1811includes two gussets 1832, 1834, however, any number of gussets 1832,1834 can be coupled to the web 1819. For example, an additional gusset1832,1834 can be coupled to the web 1819 midway through the length ofthe web 1819 to provide additional strengthening properties.

In an embodiment, flange mounts 1815, 1817 can be mounted to theexterior of the hollow tube 1813 at an end 1821,1823 as shown in FIGS.59, 60. In an embodiment, the triangular wing 1826 can be coupled to thehollow tube 1813 so that the first edge 1825 couples to the end edge1837 of the top wall 1835 of the hollow tube 1813 and the second edge1827 couples to the end edge 1839 of the rear wall 1831 of the hollowtube 1813 so that web 1819 is in the same plane as the angled member1468 of the triangular shaped prism member 1415. The triangular gusset1834 can be coupled to the hollow tube 1813 so that the first edge 1841couples to the end edge 1838 of the bottom wall 1860 of the hollow tube1813 and the second edge 1843 couples to the end edge 1842 of the frontwall 1861 of the hollow tube 1813. Illustratively, if the tube stiffener1811 is comprised of steel or high strength steel, the tube stiffener1811 can be coupled by welding.

In another embodiment, the flange mounts 1815, 1817 can be mounted tothe interior of the hollow tube 1813 as shown in FIGS. 61, 62.Illustratively, the flange mounts 1815, 1817 can be coupled to thehollow tube 1813 so that the first edge 1825 of the triangular wing 1824couples to the top wall 1835 of the hollow tube 1813 and the second edge1827 of the triangular wing 1824 couples to the rear wall 1831 of thehollow tube 1813, the first edge 1841 of the triangular gusset 1834couples the bottom wall 1866, and the second edge 1843 couples the frontwall 1861 of the hollow tube 1813 so that web 1819 is in the same planeas the angled member 1468 of the triangular shaped prism member 1415.Illustratively, if the tube stiffener 1811 is comprised of steel or highstrength steel, the tube stiffener 1811 can be coupled by welding.

In an embodiment, the horizontal bumper 30, 130, 1430, 1630 can includea tube stiffener 1911 and a hollow tube 1913 as shown in FIGS. 63, 64.While the horizontal bumper 1430 is shown illustratively, it should beunderstood that any horizontal bumper 30, 130, 1430, 1630 can includethe tube stiffener 1911. The tube stiffener 1911 is coupled to thehollow tube 1913 to prevent compaction of the horizontal bumper 1430upon impact in the event of a collision.

The tube stiffener 1911 includes a first flange mount 1915, a secondflange mount 1917 located in spaced-apart relation to the first flangemount 1915, and a corrugated web 1919 extending between the first flangemount 1915 and the second flange mount 1917 as shown in FIGS. 63, 64.The corrugated web 1919 can illustratively be any length, for example,the corrugated web 1919 can be the same length as the distance betweenthe bumper supports 1470, 1474 or can be longer or shorter, depending onthe rear impact guard 212, 512, 912, 1212, 1412, 1612. The tubestiffener 1911 can be located within the hollow tube 1913 at either end1921, 1923, or at both ends 1921 of the hollow tube below the bumpersupport members 1470, 1474, as shown in FIG. 64. In an embodiment, thetube stiffener 1911 spans the entire length of the hollow tube 1913.

The corrugated web 1919 includes a plurality of corrugates 1951, asshown in FIG. 63. Each corrugate 1951 includes a first face 1950 that isgenerally parallel with the flange mount 1915, a third face 1953 that isgenerally parallel to the first face 1950, and a second face 1952 thatis generally perpendicular to the first face 1950 and couples the firstface 1950 to the second face 1952. In an embodiment, the corrugates 1951are equally spaced. In another embodiment, the faces 1950, 1952, 1953are generally the same size. In another embodiment, the thickness oftube stiffener 1911 can range from about 0.05 to about 0.3 inches, about0.05 to 0.2 inches, about 0.1 to about 0.3 inches, or alternatively, canbe about 0.1 inches thick, about 0.2 inches thick, or about 0.25 inchesthick.

Another embodiment of a rear impact guard 2012 in accordance with thepresent disclosure is shown in FIGS. 65-68. The rear impact guard 2012includes a horizontal bumper 1630, bumper supports 2070, 2074, andbumper mounts 2071, as shown in FIGS. 65A and 65B. The rear impact guard2012 may be coupled to the floor assembly 14 of the trailer 10 in asimilar manner to the rear impact guards 12, 212, 512, 912, 1212, 1412,1612 and may additionally include the outer support bases 1660 and theinner support bases 1661. Alternatively, the rear impact guard 1612 mayuse the support bases 960, 961. The rear impact guards 2012 in FIGS. 65Aand 65B differ in a length of the end clip 967 (or removal thereof) andan overall length of the outer support bases 1660 and/or the innersupport bases 1661. In some embodiments, the angles A1 of the lowermembers 304 of the bumper support members 2070 with respect to avertical axis V may be the same or similar to the angles A2 of the reararms 1662 of the support bases 1660 with respect to the vertical axis V.This may also be the case with respect to bumper support members 2074and support bases 1661. The length (along a longitudinal axis of thetrailer 10) of one or both of the outer support bases 1660 and/or innersupport bases 1661 may be varied based on a particular application, thetype of vehicle, desired results, aerodynamics, and/or any otherfactors.

The rear impact guard 2012 includes two outer bumper support members2070 and two inner bumper support members 2074, as shown in FIGS. 65Aand 65B. The outer bumper support members 2070 are similar inconstruction and function to the outer bumper support members 1670, andthe inner bumper support members 2074 are similar in construction andfunction to the inner bumpers support members 1674. The inner bumpersupport members 2074 and the outer bumper support members 2070 extenddownwardly from the rear of the trailer and couple to the horizontalbumper 1630 with the bumper mounts 2071. In some embodiments, the bumpersupport members 2074 are replaced with bumper support members 2070 tocause the rear impact guard 2012 to include four bumper support members2070.

The two inner bumper support members 2074 are located between the twoouter bumper support members 2070 when viewing the trailer 10 from therear, as shown in FIG. 65A. Each of the bumper support members 2070,2074 includes a generally triangular shaped prism member 2013, 2015,apertures 2075, a base mount 2017, and a bumper mount 2071, as shown inFIGS. 65A, 65B, and 66. The bumper support members 2070, 2074 areconfigured to removably couple to the horizontal bumper 1630. The bumpermounts 2071 are located within a generally hollow area of the prismmembers 2013, 2015.

In some embodiments, the bumper mount 2071 is configured to allow thehorizontal bumper 1630 to be removed from the rear impact guard 2012without removing the bumper support members 2070, 2074 in the event thatthe horizontal bumper 1630 needs to be replaced. In some embodiments,each bumper support member 2070, 2074 includes three apertures 2075 forinsertion of fastener for attachment of the bumper support members 2070,2074 to the horizontal bumper 1630. In other embodiments, the apertures2075 may include more or less than three apertures.

The triangular shaped prism member 2015 of the bumper support 2074includes a rear face 2018, a front face 2020, a top face 2021, and twoside faces 2022 that cooperate to form the interior region of thetriangular shaped prism member 2015. Each side face 2022 is formed toinclude a circular aperture 2091 that extends through the side face 2022to allow access into bumper support 2074.

Illustratively, each circular aperture 2091 is formed in an upperportion of the side face 2022 as shown in FIG. 66. The circularapertures 2091 may increase energy absorption of bumper support 2074.The apertures 2091 may increase the bumper support's 2074 resistance tobuckling and improve folding during an impact to increase energyabsorption during the impact. In the illustrative embodiment, thecircular apertures 2091 have a diameter of about, or specifically, fourinches.

The top face 2021 extends in a forward direction from the rear face 2018to couple with the angled front face 2020. In some embodiments, the topface 2021 is about 10 inches long. In some embodiments, the top face2021 is about 10.37 inches long. Illustratively, the top face 2021 meetswith the angled front face 2020 and forms an inner bumper supportforward angle. In the illustrative embodiment, the inner bumper supportforward angle is about 66 degrees.

The triangular shaped prism member 2013 of bumper support 2070 includesa rear face 2032, a front face 2034, a top face 2036, and two side faces2038 that cooperate to form the interior region of the triangular shapedprism member 2013, as shown in FIG. 66. Each side face 2038 is formed toinclude a triangular aperture 2040 that extends through the side face2038 to allow access into bumper support 2070.

The top face 2036 extends in a forward direction from the rear face 2032to couple with the angled front face 2034, as shown in FIG. 66. In anillustrative embodiment, the top face 2036 has a length that is greaterthan the length of the top face 2021. In some embodiments, the top face2036 is about 17 inches long. In some embodiments, the top face 2036 isabout 17.36 inches long. Illustratively, the top face 2036 meets withthe angled front face 2034 and forms an outer bumper support forwardangle. In the illustrative embodiment, the outer bumper support forwardangle is about 49 degrees. In the illustrative embodiment, support 2070and 2074 are generally of equal height.

Illustratively, a bracket 2077 of bumper mount 2071 is C-shaped, asshown in FIGS. 67A, 67B, and 68. The bracket 2077 couples with the frontwall 1633 of the horizontal bumper 1630 to off-set the horizontal bumper1630 in a rearward direction. The bracket 2077 can be formed to includethree apertures 2079 that are configured to receive fasteners 1686therethrough to reversibly couple bumper 1630 with the bumper supports2070, 2074. In some embodiments, bumper 1630 is welded to bumpersupports 2070, 2074. In some embodiments, the bracket 2077 of the bumpermount 2071 comprises steel and is coupled to the horizontal bumper 1630with a weld.

Illustratively, the bracket 2077 includes two L-shaped side walls 2063,a rear wall 2065, and a front wall 2067 as shown in FIG. 67A. In otherembodiments, as seen in FIG. 67B, the front wall 2067 may be removed.The side walls 2063 and the rear wall 2065 are each formed to includeapertures 2079 formed to receive fasteners for coupling bracket 2077with bumper supports 2070, 2074. The rear wall 2065 couples to upperportions of the L-shaped side walls 2063 and extends partway down towardthe bottom portions of L-shaped side walls 2063. The front wall 2067illustratively extends the entire length of the L-shaped side walls2063.

In some embodiments, the two L-shaped side walls 2063 and the rear wall2065 are folded from a sheet of material and the front wall 2067 iswelded to side walls 2063 to form the bracket 2077. In otherembodiments, bracket 2077 is formed from a rectangular tube of materialwith portions cut away to form L-shaped side walls 2063. As shown inFIG. 68, L-shaped side walls 2063 receive a portion of bumper 1630. Inthe illustrative embodiment, bracket 2077 is welded to bumper 1630.

In some embodiments, the horizontal bumper 30, 130, 1430, 1630 includesa tube stiffener 2011 and a hollow tube 2014 as shown in FIGS. 65A, 65B,and 66. While the horizontal bumper 1630 is shown illustratively, anyhorizontal bumper 30, 130, 1430, 1430 may include the tube stiffener2011.

In some embodiments, the tube stiffener 2011 extends the entire lengthof the hollow tube 2014, as shown in FIGS. 65A and 65B. In otherembodiments, the tube stiffener 2011 may extend along only a portion ofthe length of the hollow tube 2014 or may include spaced apart segmentsalong the entire length of the hollow tube 2014. The tube stiffener 2011includes two flange mounts 2016 and a web 2019 extending between the twoflange mounts 2016, as shown in FIGS. 65A, 65B, and 66. The tubestiffener 2011 is coupled to the hollow tube 2014 and may preventcompaction of the horizontal bumper 1630 upon impact in the event of acollision.

Referring to FIG. 69, an illustrative embodiment depicting how any ofthe bumper support members disclosed herein may be attached to thetrailer 10 utilizing support bases 960, 961 or 1660, 1661 (or any othersupport bases) is shown. The attachment of support bases 960, 961 or1660, 1661 will be discussed with reference to FIGS. 8, 48, and 49(depicting vertical bumper support members 272 and support bases 1660,1661, respectively), but one skilled in the art will understand thatsuch attachment may be utilized for any vertical bumper support membersor support bases disclosed herein, or any combinations thereof.

Referring to FIG. 69 and as described above, the floor assembly 14generally includes two longitudinal slide rails 36 and a plurality ofcross-members 38 that are perpendicularly aligned with respect to theslide rails 36. A fantail 58 is welded or otherwise attached to a rearend of the floor assembly 14. As seen in FIG. 69, the fantail 58generally includes a front wall 2100, a stepped top wall 2102, and arear wall 2104. The generally horizontally oriented base plate 60extends a length of the fantail 58 and is welded along its length to thefantail 58. Strapping angle members 2106 are attached, for example, bywelding to each end of the fantail 58 and are generally L-shaped. Eachstrapping angle member 2106 includes a front plate 2110, a bottom plate2112 extending generally perpendicularly from the front plate 2110, anda rear lip 2114 extending generally perpendicularly from the bottomplate 2112. An upper edge of the front plate 2110 of the strapping anglemember 2106 is welded to the front wall 2100 of the fantail 58 and anupper edge of the rear lip 2114 is welded to a bottom surface of thebaseplate 60. An L-shaped web 2116 is positioned at opposing ends of thetrailer 12 within the fantail 58 and strapping angle member 2106. Moreparticularly, front, bottom, and rear edges 2220, 2222, 2224 of the web2116 are welded to the strapping angle member 2106 and an inner upperedge 2226 of the web 2116 is welded to the bottom surface of thebaseplate 60.

Referring to FIGS. 48 and 69, the front arm 1664 of the support base1660 is attached to the front plate 2110 of the strapping angle member2106, by inserting fasteners 2202 through the apertures 1627 in thefront arm 1664 and through corresponding apertures (not shown) in thefront plate 2110 of the strapping angle member 2106. In otherillustrative embodiments, the front arm 1664 of the support base 1660may be attached to the front plate 2110 of the strapping angle member2106 (or to the fantail 58) by other suitable means, for example,welding. The top plate 1669 of the support base 1660 may also be weldedor otherwise attached to lower surfaces of one or more of the crossmembers 38.

Now referring to FIGS. 66 and. 69, the bumper support member 272 may beattached to the rear lip 2114 of the strapping angle member 2106 byinserting fasteners 2206 through the apertures 280 in the verticalplates 276 of the bumper support member 272 and through correspondingapertures (not shown) in the rear lip 2114 of the strapping angle member2106. Fasteners 2210 are also inserted through the apertures 308 in theupper member 302 of the bumper support member 272 and throughcorresponding apertures in the bottom plate 2112 of the strapping anglemember 2106. In other illustrative embodiments, one or both sets offasteners 2206, 2210 may be replaced with any other suitable attachmentmeans, for example, including welding.

As seen in FIG. 69, the bumper support member 276 is coupled directly tothe strapping angle member 2106, which is welded to the fantail 58,which is attached, for example by bolting or welding, to the floorassembly 14. The bumper support member 276 is not coupled directly tothe support base 1660, but instead, is simply in contact with thesupport base 1660 or floating below the support base 1660. Moreparticularly, the upper member 302 of the bumper support member 276 isspaced from or in contact with the lower surface 1629 of the supportbase 1660. In this manner, the bumper support member 276 is not directlycoupled to the floor assembly 14 or any of its support members. As such,load (for example, from pressure against the bumper support member(s)272 and/or horizontal bumper) may be transferred from the bumper supportmember 272 without a direct connection to the floor assembly 14. Thisfloating connection may provide added protection to the floor assembly14 upon rear impact. As noted above, the above-described positioning ofthe bumper support member 276 and support base 1660 may be utilized withany of the bumper support members and/or support bases, as describedherein.

Portions of a further embodiment of a rear impact guard 2212 aredepicted in FIGS. 70-72. The rear impact guard 2212 is configured to beutilized with, for example, bumper support members of the presentdisclosure and previously-installed bumper support members. The rearimpact guard 2212 includes a bumper 2230 that may be similar to any ofthe bumpers as disclosed herein. Two outboard brackets 2077, asdescribed in detail with respect to FIGS. 67A and 67B, may be attachedto opposing ends 2232, 2234 of the bumper. Alternatively, the outboardbrackets 2077 may be disposed at any other suitable location. Thebrackets 2077 are configured to receive any of the bumper supportmembers disclosed herein, as detailed above, for example, the bumpersupport member 272 of FIG. 8. Two inboard, T-shaped brackets 2240 areattached to the bumper 2230 and spaced inwardly from the outboardbrackets 2077. Each T-shaped bracket 2240 generally includes a rearplate 2242 welded or other otherwise attached to a top surface 2244 ofthe bumper 2230 and having at least one aperture 2246 extendingtherethrough and adapted to accept fasteners (not shown). Each T-shapedbracket 2240 further includes a transverse plate 2250 attached andgenerally perpendicular to the rear plate 2242. The transverse plate2250 is also attached to the top surface 2244 of the bumper 2230 bywelding or any other suitable means. The transverse plate 2250 furtherincludes a finger 2252 that extends rearwardly and downwardly such thatan inner surface 2254 of the finger 2252 is positioned adjacent a frontsurface 2256 of the bumper 2230. The finger 2252 may be welded orattached by any other suitable means to the front surface 2256 of thebumper 2230. The transverse plate 2250 and/or the finger 2252 mayinclude at least one aperture 2260 that is configured to accept afastener (not shown). The fasteners used to secure the brackets 2077 and2240 to the bumper support members 272, 2300, respectively, may allowfor easy replacement of the bumper 2230 should the bumper 2230 needreplacing. In other illustrative embodiments, the bumper support members272, 2300 may be attached to the brackets 2077, 2240, respectively, bywelding or any other suitable attachment mechanism.

As seen in FIGS. 71-73, an exemplary previously-installed bumper supportmember 2300 is depicted. The bumper support member 2300 generallyincludes a rear plate 2302 having inwardly turned flanges 2304. A firstset of apertures 2306 are positioned in a lower portion 2308 of the rearplate 2302 and a second set of apertures 2310 are positioned in an upperportion 2312 of the vertical plate 2302. The bumper support member 2300further includes a generally triangular support member 2314 having anupper horizontal support member 2316, an angled support member 2318extending between the bumper 2230 and the upper support 2316, and atriangular web 2322 extending between the rear plate 2302, the uppersupport member 2316, and the angled support member 2318. The web 2322may include an aperture 2324 therethrough that may be circular or anyother shape.

As seen in FIG. 71, the bumper support member 2300 is attached to thebumper 2230 using the T-shaped bracket 2240. More particularly, thebumper support member 2300 is inserted over the T-shaped bracket 2240and fasteners (not shown) are installed through the first set ofapertures 2306 in the lower portion 2308 of the vertical plate 2302 andthe apertures 2246 in the rear plate 2242 of the T-shaped bracket 2240.A fastener (not shown) is also installed through the aperture 2260 inthe transverse plate 2250 and an aperture (not shown) in the web 2322 ofthe bumper support member 2300. As noted above and as seen in FIG. 72,the rear impact guard 2232 may include outboard bumper support members272 (or any of the bumper support members disclosed herein) andpreviously-installed inboard bumper support members 2300. In otherembodiments, as seen in FIG. 73, a rear impact guard 2400 may includeany number of previously-installed bumper support members 2300, forexample four, with any of the bumpers of the present disclosure, forexample, the bumper 2230.

Any of the rear impact guards as described herein may replace apreviously-installed rear impact guard or portions of apreviously-installed rear impact guard through a retrofit process. Asdepicted in FIG. 74, the retrofit process 3000 includes the step offirst removing the previously-installed rear impact guard at Step 3002such that nothing is attached to the fantail 58 or a rear end of thetrailer 10. In other embodiments, as discussed herein, only portions ofthe previously-installed rear impact guard may be removed (for example,the bumper on a rear impact guard having only two bumper support membersthat are spaced outwardly from a longitudinal axis of the trailer andinwardly from edges of the bumper, may be removed). In the case whereonly the bumper is removed, outer bumper support members and a newbumper may be retrofit to inner bumper support members of apreviously-installed rear impact guard.

Once all or a portion of the previously-installed rear impact guard isremoved, any other components attaching the rear impact guard to thetrailer are removed at Step 3004. With reference to FIG. 47, the processof FIG. 74 further includes the step of welding the inboard supportbases 1661 to the slide rails 36 at Step 3006 (if the old inboardsupport bases are not being used) and the step of welding the outboardsupport bases 1660 to one or more cross-members 38 at Step 3008.Thereafter, the strapping angle members 2106 are attached to ends of thefantail 58 at Step 2010 and the strapping angle members 2106 are boltedto the support bases 1660 (described above with respect to FIG. 69) atStep 3012. Any exposed steel components are coated at Step 3014 toprevent corrosion. At Step 3014, the outboard bumper support members1670 and/or the inboard bumper support members 1674 are attached to thestrapping angle members 2106, as described in detail above. At Step3016, the horizontal bumper 1630 (as seen in FIG. 47, or any otherbumper disclosed herein) may be attached in any manner as discussedherein. While the retrofit process is discussed in relation to oneembodiment, the same or a similar retrofit process may be utilized forany of the embodiments disclosed herein.

While the steps of the retrofit process have been described as being ina particular order, one skilled in the art will understand that some ofthe steps described in the retrofit process 3000 may be performed in adifferent order. Still further, one or more of the preceding steps maybe completely omitted, for example, if one or more supports form apreviously-installed rear impact guard is to be utilized in conjunctionwith one or more the support bases 960, 961, support bases 1660, 1661,or any other supports described herein, and/or any of the bumpers asdescribed herein.

A number of embodiments herein, for example as seen in FIGS. 34, 43, 44,47, 65A, 65B, 69, 72, and 73, depict one or more support bases and/orbumper support members that are spaced outwardly from a longitudinalaxis of the trailer 10 and which are disposed adjacent opposing sides ofthe floor assembly 14, the sidewalls 16, the rear end wall assembly 18,and/or cross-members 38 such that the support bases and/or bumpersupport members are positioned with outer edges thereof aligned withouter edges of one or more of outer edges of the floor assembly 14, thesidewalls 16, the rear end wall assembly 18, and/or cross-members 38. Inother illustrative embodiments, the outer edges of support bases and/orbumper support members are spaced inwardly from outer edges of one ormore of outer edges of the floor assembly 14, the sidewalls 16, the rearend wall assembly 18, and/or cross-members 38.

While the rear impact guards of the present disclosure are shown asbeing attached to a trailer, any of the rear impact guards as disclosedherein may be attached to truck bodies, dry van or refrigeratedtrailers, refrigerated dry vans, flat beds, tanks, or any othervehicles.

While rear impact guards are generally utilized to prevent othervehicles in a rear-impact collision with such a trailer from travelingbeyond the rear extremity of the trailer and into an area beneath thefloor assembly of the trailer, testing has shown that the rear impactguards disclosed herein also improve aerodynamics.

While the disclosure has been illustrated and described in detail in theforegoing drawings and description, the same is to be considered asexemplary and not restrictive in character, it being understood thatonly illustrative embodiments thereof have been shown and described andthat all changes and modifications that come within the spirit of thedisclosure are desired to be protected.

What is claimed is:
 1. A rear impact guard configured to be coupled to arear end of a vehicle, comprising: first and second support basesconfigured to be coupled to the rear end of the vehicle and configuredto be positioned below a floor assembly of the vehicle, wherein thefirst and second support bases are spaced from one another along a widthof the vehicle; first and second bumper support members associated withthe first and second support bases, respectively; wherein the first andsecond bumper support members are configured to be coupled to the rearend of the trailer; and wherein at least a portion of an upper surfaceof the first bumper support member is in contact with at least a portionof a lower surface of the first support base and at least a portion ofan upper surface of the second bumper support member is in contact withat least a portion of a lower surface of the second support base; and ahorizontal bumper mounted to lower ends of the first and second bumpersupport members; wherein the first bumper support member and the secondbumper support member are configured to be coupled to the left of alongitudinal axis of the vehicle.
 2. The rear impact guard of claim 1,further comprising: third and fourth support bases configured to becoupled to the rear end of the vehicle and configured to be positionedbelow the floor assembly of the vehicle; third and fourth bumper supportmembers associated with the third and fourth support bases,respectively; wherein the third and fourth bumper support members areconfigured to be coupled to the rear end of the trailer; and wherein atleast a portion of an upper surface of the third bumper support memberis in contact with at least a portion of a lower surface of the thirdsupport base and at least a portion of an upper surface of the fourthbumper support member is in contact with at least a portion of a lowersurface of the fourth support base; and wherein lower ends of the thirdand fourth bumper support members are mounted to the horizontal bumper;wherein the third bumper support member and the fourth support base areconfigured to be coupled to the right of a longitudinal axis of thevehicle.
 3. The rear impact guard of claim 2, wherein each of the firstand fourth support bases is configured to be coupled to at least onecross-member forming a portion of the floor assembly of the vehicle, theat least one cross-member being perpendicular to a longitudinal axis ofthe vehicle, and each of the second and third support bases isconfigured to be coupled to a slide rail forming a portion of the floorassembly.
 4. The rear impact guard of claim 2, wherein each of thefirst, second, third, and fourth support bases further comprises: a topplate configured for attachment to the floor assembly of the vehicle; afront arm that extends between and is perpendicular to the top plate andthe lower surface, wherein the front arm is configured for attachment toa fantail of the vehicle; and a rear arm extending between the lowersurface and the top plate.
 5. The rear impact guard of claim 4, whereinthe lower surface of each of the first, second, third, and fourthsupport bases has a length that is less than a length of the top platesuch that the rear arm extends at an angle between the lower surface andthe top plate.
 6. The rear impact guard of claim 5, wherein each of thefirst, second, third, and fourth support bases further includes: a webextending between and perpendicular to the top plate and furtherextending between the front and rear arms; and at least one gussetextending outwardly from the web between the top plate and the lowersurface.
 7. The rear impact guard of claim 2, wherein the first andfourth bumper support members are the same and have a firstconfiguration, the second and third bumper support members are the sameand have a second configuration, and the first configuration isdifferent than the second configuration.
 8. A rear impact guardconfigured to be coupled to a rear end of a vehicle, comprising: firstand second bumper support members configured to be coupled to the rearend of the vehicle and spaced outwardly from a longitudinal axis of thevehicle; third and fourth bumper support members configured to becoupled to the rear end of the vehicle, the third bumper support memberbeing spaced outwardly of the first bumper support member and the fourthbumper support member being spaced outwardly of the second bumpersupport member; and a horizontal bumper mounted to lower ends of thefirst, second, third, and fourth bumper support members; wherein thefirst and second bumper support members have a first configuration, thethird and fourth bumper support members have a second configuration, andthe first configuration is different than the second configuration. 9.The rear impact guard of claim 8, wherein the first configurationincludes having a circular aperture in walls forming the first andsecond bumper support members and the second configuration includeshaving a triangular aperture in walls forming the third and fourthbumper support members.
 10. The rear impact guard of claim 8, wherein:the first configuration includes the first and second bumper supportmembers having a first upper length parallel to a longitudinal axis ofthe vehicle; the second configuration includes the third and fourthbumper support members having a second upper length parallel to thelongitudinal axis of the vehicle; and the second upper length is greaterthan the first upper length.
 11. The rear impact guard of claim 8,wherein each of the third and fourth bumper support members includes ahollow, generally triangular prism member, wherein the triangular prismmember includes first and second generally triangular-shaped faces, avertical member, a horizontal member, and an angled member, and thevertical, horizontal, and angled members are each positioned between andcoupled to outer edges of the first and second triangular-shaped faces.12. The rear impact guard of claim 11, wherein each triangular-shapedface includes a generally triangular-shaped aperture.
 13. The rearimpact guard of claim 12, wherein each of the first and second bumpersupport members includes a hollow, generally triangular prism member,wherein the triangular prism member includes third and fourth generallytriangular-shaped faces, a vertical member, a horizontal member, and anangled member, and the vertical, horizontal, and angled members are eachpositioned between and coupled to outer edges of the third and fourthtriangular-shaped faces.
 14. The rear impact guard of claim 13, whereineach triangular-shaped face of the first and second bumper supportmembers includes a circular aperture.
 15. The rear impact guard of claim8, further including a tube stiffener located within an interior spacedof the horizontal bumper.
 16. The rear impact guard of claim 8, furtherincluding bumper mounts for mounting the first and second bumper supportmembers to the horizontal bumper, each bumper mount comprising: ac-shaped bracket configured to be positioned adjacent a top surface ofthe horizontal bumper; and at least one finger or wall extendingoutwardly from the c-shaped bracket and configured to be coupled to afront surface of the horizontal bumper; wherein the first and secondbumper support mounts receive the c-shaped bracket within lower openends thereof and at least one fastener extends through the c-shapedbracket and the lower open ends of the first and second bumper supports.17. A rear impact guard configured to be coupled to a rear end of avehicle, comprising: a bumper support member extending downwardly fromand coupled to the rear end of the vehicle, a horizontal bumper mountedat a lower end of the bumper support member, wherein the horizontalbumper extends generally perpendicular to the bumper support member, anda tube stiffener located in an interior space of the horizontal bumper.18. The rear impact guard of claim 17, wherein the tube stiffenerincludes a first flange mount, a second flange mount located inspaced-apart relation to the first flange mount, and a web located andextending between the first flange mount and the second flange mount.19. The rear impact guard of claim 17, wherein the tube stiffenerextends an entire length of the horizontal bumper.
 20. The rear impactguard of claim 17, wherein the tube stiffener is comprised of steel andis coupled to an interior wall at the first end of the horizontal bumperor coupled to an end edge of the first end of the horizontal bumper.